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Appendix A

1. 3 22 200 200 Drive Status Register Continued Bit 10 Hex Value 0400H Sug Var Name PH ABC Range N A Access Read Only UDC Error Code N A LED N A Description The A C Line Phase ABC bit is equal to one when the A C line is phased ABC 181 182 183 If needed the application program may test this bit to determine the A C line phasing This bit is equal to zero when the A C line is phased ACB Bit 11 is set equal to one when the phasing has been detected The system automatically adapts to either ABC or ACB phasing without user pro gramming This bit is checked by the armature and field algorithms alpha tests and identification tests Bit 11 Hex Value 0800H Var Name PH_RDYO Range N A Access Read Only UDC Error Code N A LED N A Description The Phase Synchronization Ready bit is set equal to one when the A C line phasing has been detected If the A C line phasing has not been detected check the incoming A C power lines When this bit is set the status of bit 10 is valid Bit 14 Hex Value 4000H Sug Var Name CCLK Range N A Access Read Only UDC Error Code N A LED N A Description The PMI Processor sets the CCLK Synchronized bit when CCLK in the UDC module is synchronized with CCLK in the PMI Processor This bit will be equal to zero when CCLK is not turned on in the AutoMax rack or if there have been two consecutive instances when CCLK is not
2. Var Name UDC_PBO Range N A Access Read only UDC Error Code N A LED N A Description The Pushbutton Input bit is on when the pushbutton is pressed Bit 1 Hex Value 0002H Sug Var Name SWIT UP Range N A Access Read only UDC Error Code N A LED N A Description The Switch Up Input bit is on when the switch is in the up position 3 40 1000 UDC Test Switch Inputs Register Continued Bit 2 Hex Value 0004H Sug Var Name SWIT DNO Range N A Access Read only UDC Error Code N A LED N A Description The Switch Down Input bit is on when the switch is in the down position Bit 8 Hex Value 01 00H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED OS OK on the UDC module Description Status of the Operating System OK LED on the UDC module 0 Off 1 On Bit 9 Hex Value 0200H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED COMM A OK on the UDC module Description Status of the COMM A OK LED on UDC module 0 Off 1 On Bit 10 Hex Value 0400H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED DRV A FLT on the UDC module Description Status of the Drive A Fault LED on the UDC module 0 Off 1 On Bit 11 Hex Value 0800H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED COMM B OK on the UDC module Description Status of the COMM B OK LED on
3. User supplied external CTs must be Appendix E Continued 380 and 460 Line Voltage S6 Drive Model Number HP Kw D C Output Volts D C Output Amps CT Turns Ratio 30300 1 5 2 15 500 10 27 100 1 500 35 500 301 00 5 1 500 73 007 500 85 250 2000 500 320 480 3060 1 500 640 800 7770 1 500 800 960 7770 1 500 11201600 100001 500 2000 100001 840 55 10 5 6 800 600 666 5230 1 600 1250 10500 1 User supplied external CTs must be provided 380 and 460 VAC Line Voltage S6R Drive Number KW DC Output Volts DC Output Amps CT Tums Ratio 3O3lo ls 215 50 1027 101 3030s5B 520 371 35 o 303111 5 16 60 500 30 1 00 500 1 30311 SE 3040 2230 50 _ B O 30312 5E 501 50 35 110 500 85250 2001 sosse f 200300 150 220 500 320 480 3860 1 30314 SB 400 500 300 375 500 640 800 7770 1 f soso 500 600 875440 soo 8003900 77i ____296767 7001000 20740 TOM _ 296769 10001 250 04033 200 19091 Seem 8103210 SIMA 8405110 S6R2NA 2000 1 840 54 10 S 6R 450A 840 56 10 S6R 800A A 840 58 10 S6R 1500A User supplied external CTs must be provided E 2 39 35 399 ___ 9 93 Appendix E Continued 575 VAC Line Voltag
4. se Mena m hno jeu 46151661 ueos ena SUM einpow oan ee YIN 9 ydnuequl sed SULIS ui anjer Figure 4 3 Nth Scan Interrupts 4 10 5 0 ON LINE OPERATION DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL AND OTHER APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE The ON LINE command in the System Configurator and the Task Manager applications allows you to access options such as loading running and monitoring tasks in the rack All of the options are described in detail in the AutoMax Programming Executing instruction manual The following sections provide a summary of some of the options as applied to the UDC module and UDC tasks Note that you must load operating systems onto the Processor modules and UDC modules in the rack before attempting to use any of the on line options 51 Loading the UDC Module s Operating System Like the AutoMax Processor the UDC module requires an operating system You can load the operating system to a UDC module by using the Load Operating System command from the Command menu in the System Configurator Refer to the AutoMax Programming Executive instruction manual for the procedure You m
5. 205 1 205 Interlock Register Continued Bit 2 Hex Value 0004H Sug Var Name WCI_GANO Range N A Access Read Only UDC Error Code N A LED N A Description The CML Gains Not Loaded bit is set if the armature gains are zero i e have not been auto tuned for or if a UDC task containing the pre defined gain variables has not been loaded Bit 3 Hex Value 0008H Sug Var Name WCI Range N A Access Read Only UDC Error Code N A LED N A Description The CML Faults Need to be Reset bit is set if previous armature faults register 202A 202 have not been cleared Bit 4 Hex Value 001 OH Sug Var Name Range N A Access Read Only UDC Error Code N A LED N A Description The Run Permissive Input is Missing bit is set if the run permissive input on the Resolver amp Drive V O module is not on Bit 5 Hex Value 0020H Var WCI_FNRO Range N A Access Read Only UDC Error Code N A LED N A Description The Field Not Ready bit is set if the single phase field is not on Note that the CML can not be executed if the field is not on Bit 6 Hex Value 0040H Sug Var Name WCI_FNA Range N A Access Read Only UDC Error Code N A LED N A Description The Field Not Allowed bit is set if the single phase field is requested when the armature identification test or the armature alpha test is running 2051205 Interlock Register Continued Bit 7
6. Hex Value 0080H Var Name WCI_MCRO Range N A Access Read Only UDC Error Code N A LED N A Description The M Contactor Not Closed bit is set if the M Contactor did not close at the expected time Bit 8 Hex Value 01 OOH Sug Var Name WFI ILL Range N A Access Read Only UDC Error Code N A LED N A Description The More Than One Field Request bit is set when more than one incompatible Field operating mode is requested at a time in register 100 1 100 The following operating modes are mutu ally exclusive e Field Alpha Test e Field Identification Test e Field Run This bit is also set if you have attempted to restart the drive without resetting the appropriate com mand bits from register 100 1 100 Recall that the bits in register 100 1 100 are edge sensitive See Appendix G for additional information Bit 9 Hex Value 0200H Sug Var WFI_CNFO Range N A Access Read Only UDC Error Code N A LED N A Description The Field Parameters Are Not Loaded bit is set if the field configuration parameters have not been downloaded into the UDC module from the Programming Executive Bit 10 Hex Value 0400H Var Name WFI_GANO Range N A Access Read Only UDC Error Code N A LED N A Description The Field Gains Not Loaded bit is set if field gains are zero i e have not been auto tuned for or a UDC task containing the pre defined gain variables has not been loaded B
7. Only one drive can be selected at a time when two drives are shown on the screen e the Drive A option will make drive A the selected drive e the Drive B option will make drive B the selected drive Entered commands will only affect the selected drive Step 2 Ifa rail is to be connected to the PMI s rail ports click the appropriate rail port either 0 or 1 Select Add under the Configure menu to add the rail to the rail ports You can choose from the following rail devices e M N 450001 Digital I O Rail e M N 45C630 4 Decade Thumbwheel Switch Input Module e M N 456631 4 Digit LED Output Module e M N 61 C345 4 Channel Analog Current Input Rail e M N 61 C346 4 Channel Analog Voltage Input Rail e M N 61 C350 2 Channel Analog Voltage Input Output Rail Step 3 Step 4 e M N 61 C351 2 Channel Analog Current Input Output Rail e M N 61 C365 4 Channel Analog Current Output Rail e M N 61C366 4 Channel Analog Voltage Output Rail Click OK and the device will be added to the screen If you are adding a digital I O rail you will need to configure the I O modules that the rail contains Double click the rail to display the expanded digital I O rail screen To add an I O module select the module s slot by moving the cursor to it and clicking it Select the Add option from the Configure menu for a list of the available modules Select the appropriate module and click OK Zoom out to return to the PMI screen Rack Configurator Note that yo
8. SUBLULUOS Latch every scan Write registers that are inputs to task A every scan registers that are outputs from task B Task B can act on Task A outputs within a scan Figure 4 1 Typical UDC Task Scan All common input values for task A are first read from the dual port memory and then stored in a local buffer in order to have a consistent context for evaluation Task A is then executed After task A has been executed the common output values from task A are written from the local memory buffer to dual port memory All common input values for task B are then read from dual port memory and stored in a local buffer in order to have a consistent context for evaluation Task B is then executed Note that task B can act on task A outputs within one scan After task B has been executed the common output values from task B are written from the local memory buffer to dual port memory The only exception to this pattern are the common variables in the scan application register area These registers are updated immediately before every Nth scan only as defined by the user See section 4 3 and figure 4 3 for more information on Nth scan interrupts See section 4 2 3 for more information on the command and feedback messages 4 2 1 Typical Structure of a UDC Task The typical structure of a UDC task is described below The first part of the task described in steps 1 to 4 below is considered task initialization This p
9. wwsoo2 HR2000 Video Training Videotape WWS005 Basics of A C Drives Videotape For details and prices on these courses audio visual products and FREE Training Schedule Brochure HD 405 contact Industrial Training Department Reliance Electric 35000 Curtis Boulevard Eastlake Ohio 44095 Call Toll Free 800 RELIANCE 800 735 4262 RELIANCE r Data or Prices subject to change without notice ELE Reliance Electric 24703 Euclid Avenue Cleveland Ohio 44117 216 266 7000 RELIANCE ELECTRICI 7 Printed in USA s 3006 1 February 1995
10. N A LED N A Description SCR 4 Fault Forward Bridge Bit 4 Hex Value 001 OH Sug Var Name SCR_050 Range N A Access Read Only UDG Error Code N A LED N A Description SCR 5 Fault Forward Bridge Bit 5 Hex Value 0020H Sug Var Name SCR 06 Range N A Access Read Only UDG Error Code N A LED N A Description SCR 6 Fault Forward Bridge Bit 6 Hex Value 0040H Sug Var Name SCR 1 Range N A Access Read Only UDG Error Code N A LED N A Description SCR 11 Fault Reverse Bit 7 Hex Value 0080H Sug Name SCR 1 20 Range N A Access Read Only UDG Error Code N A LED N A Description SCR 12 Fault Reverse Bit 8 Hex Value 01 OOH Sug Name SCR 1 30 Range N A Access Read Only UDG Error Code N A LED N A Description SCR 13 Fault Reverse Bit 9 Hex Value 0200H Sug Var Name SCR 1 40 Range N A Access Read Only UDG Error Code N A LED N A Description SCR 14 Fault Reverse 2047 204 SCR Diagnostic Register Continued Bit 10 Hex Value 0400H Var Name SCR 159 Range N A Access Read Only UDC Error Code N A LED N A Description SCR 15 Fault Reverse Bridge Blt 11 Hex Value 0800H Sug Var Name SCR 16 Range N A Access Read Only UDC Error Code N A LED N A Description SCR 16 Fault Reverse Bridge 2051 205 Interlock Register Interlock tests are executed whenever bits O 7 of registe
11. Name FLT_PTMO Range N A Access Read Only UDC Error Code 1011 LED OK on the DC Power Technology module Description The Power Technology Fault bit is set when the watchdog times out on the D C Power Technology module When this bit is set the gate firing circuitry will be disabled Bit 12 Hex Value 1 Sug Name FLT PSQ Range N A Access Read Only UDC Error Code 1012 LED PWR OK on the Power Supply module Description The PMI Power Supply Fault bit is set when the PMI power supply is not working correctly Bit 13 Hex Value 2000H Var Name FLT_RWO Range N A Access Read Only UDC Error Code 1013 LED N A Description The PMI Read Write Failure Fault bit is set when there is a bus fault in the PMI rack This is indicated when the Resolver and Drive l O module and the DC Power Technology module do not respond to requests from the PMI Processor This error indicates that there is a hardware problem in the rack Bit 14 Hex Value 4000H Sug Var Name FLT RUNG Range N A Access Read Only UDC Error Code 1014 LED N A Description The UDC Run Fault bit is set when the UDC task stops while the minor loop is running in the PMI Processor 202 1 202 Drive Fault Register Continued Bit 15 Hex Value 8000H Sug Var Name FLT COMO Range N A Access Read Only UDC Error Code 1015 LED N A Description The Communication Lost Fault bit is set when the fiber opt
12. Refer to register 1061 106 for more information Figure 2 8 PMI Meter Port Parameters SD3000 2 11 2 3 2 12 PMI meter ports can also be set up on line using the Setup UDC selection from the Monitor menu as described in the AutoMax Programming Executive instruction manual If the meter ports are set up during parameter entry the information is loaded onto the UDC module in the AutoMax rack along with all other parameter data The meter port setup can then be changed on line under Setup UDC but this method would not actually write over the PMI meter port setup that was loaded to the rack Instead the new setup would be valid only until there was a Stop All or a power cycle in which case the original setup would be used to determine what data to send out of the meter ports Generating the Drive Parameter Files and Printing Drive Parameters When you have completed all of the drive parameter screens you can select Close to leave the Parameter Entry screens and return to the master rack diagram with the UDC module selected Zoom out or select the Exit command from the Configure menu to return to the System Configurator You can generate the drive parameter files by using the steps that follow Step 1 From the System Configurator access the Task Manager by selecting the Manage Tasks command from the Rack menu Step 2 Select the Generate Configuration command from the Commands menu Step 3 Check the Generate Dri
13. 1 1 volt EMF_VFB 21141211 feedback 4095 100 FML_FB 2121 212 Field amps fdbk 100 1 amp FLD_IFB 2131 213 Arm field voltage feedback FLD_VFB 214 1214 User analog input Al 2048 lov to 2047 10V 2151 215 Resolver scan position RES_SCN_POS 32768 to 32767 2161 216 Resolver strobe position 32768 to 32767 RES_STR_POS Appendix A Continued 300 599 Application scan A B registers updated every UDC MODULE TEST INPUTS 1000 Switches Bit 0 UDC pushbutton UDC_PB 1 UDC switch UP position SWIT_UP 2 UDC switch DOWN position SWIT_DN LEDs 80S OK 9 Comm A OK 10 Drive A fault 11 Comm BOK 12 Drive B fault METER PORT SETUP 1001 Initiate change in setup non zero value 1002 Port 1 UDC register number 0 2047 1003 Port 1 bit number 100 115 0 all bits 1004 Port 1 maximum value 1005 Port 1 minimum value 1006 Port 2 UDC register number 0 2047 1007 Port 2 bit number 100 115 0 all bits 1008 Port 2 maximum value 1009 Port 2 minimum value 1010 Port 3 UDC register number 0 2047 1011 Port 3 bitnumber 100 115 0 all bits 1012 Port 3 maximum value 1013 Port 3 minimum value 1014 Port 4 UDC register number 0 2047 1015 Port 4 bit number 100 115 0 all bits 1016 Port 4 maximum value 1017 Port 4 minimum value 1300 1599 Application registers updated every Nth scan AB INTERRUPT STATUS and CONTROL ISCR 2000 Interrupt status and control UDC_ISCR Bii 0 1
14. 1 216 Bit 10 Hex Value 0400H Var Name NO_TBWO Range N A Access Read Write UDC Error Code N A LED N A Description The Disable Broken Wire Detection bit is set to disable the resolver broken wire test When the test is disabled a broken resolver wire will not shut the drive down This bit can only be used if No Speed Feedback is selected on the UDC Configuration Parameter Speed Feedback data screen If a resolver is selected for speed feedback this bit is ignored and the broken wire test is enabled 101 101 I O Control Register Continued Bit 15 Hex Value 8000H Sug Var Name UDC_LB Range N A Access Read Write UDC Error Code N A LED N A Description The UDC Module External Loopback bit is set to enable the external loopback test on the UDC module s fiber optic ports Register 101 bit 15 controls the COMM A test while register 1101 bit 15 controls the COMM B test Note that this bit must be set to 0 before the loopback connector is removed from the UDC module s fiber optic ports Refer to the Fiber Optic Cabling instruction manual S 3009 for additional information 1021 102 Armature Test Angle Register Hex Value N A Sug Var Name CML_ALPHA Range 5 to 180 Access Read Write UDC Error Code N A LED N A Description The value in the Armature Test Angle register is the firing angle for the armature alpha test Firing angles can range from 180 full off to 5 full
15. A and Port B o Cr ER 3i 3 3 3 Command Registers Registers 100 1 99 1 100 1199 The Command Registers view is used to configure command registers These registers are used for command data sent to the PMI by the UDC module at the end of every scan of the UDC Processor Note that the bits in these registers except bit 15 in register 100 1 100 are used to command action only and do not indicate the status of the action commanded The feedback registers registers 2001 200 to 299 1 299 are provided for this purpose The status of the command registers is not retained after a Stop All 1001 100 Drive Control Register The Drive Control register contains the bits that control the operation of the drive The SD3000 drive can operate in one of several modes as shown in Appendix G The default operating mode is idle the other modes are selected in the Drive Control register Each of these modes is described in de tail in the SD3000 Diagnostics Troubleshooting and Start Up Guidelines instruction manual All bits in this register except bit 15 can only be written to by a task on an AutoMax Processor it cannot be written to by a task on a UDC module All read write bits in this register are edge sensitive and must be maintained in order to assert the commands Bit 0 Hex Value 0001 H Sug Var Name RUNG Range N A Access Read Write UDC Error Code N A LED N A Description The Current Minor Loop Run bit is set t
16. AND BITS IN THE UDC MODULE THAT ARE DESCRIBED AS READ ONLY OR FOR SYSTEM USE ONLY MUST NOT BE WRITTEN TO BY THE USER WRITING TO THESE REGISTERS AND BITS MAY RESULT IN IMPROPER SYSTEM OPERATION FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY The Variable Configurator application in the AutoMax Programming Executive is used to assign common variable names to the dual port memory registers on the UDC module You can access these variable names by declaring them using the BASIC statement COMMON The dual port memory has 2048 16 bit registers that are available to the AutoMax Processor and to the tasks that run on the UDC module The drive A and drive B registers that are assigned variable names will be latched into internal memory at the beginning of every scan of the UDC task to provide for a consistent context for evaluation The UDC tasks A and B may be started and stopped independently of each other At the end of the scan the variables that have changed will be written back to the dual port memory Note that the dual port memory on the UDC module is treated like I O data in terms of how the data is affected by Stop All commands and power cycling You can access the Variable Configurator by selecting Configure Variables from the Configure menu in the Rack Configurator Refer to the AutoMax Programming Executive instruction manual for the procedures used to configure variables The sections that follow describe the registers
17. ASE XENONY suonduunssy 2088902014 INd SINPON oan son 02 oesul OL 1058620 4 Flow for UDC Module and Data Time Figure 42 4 8 4 3 AutoMax Processor Task and UDC Task Coordination Recall that all tasks running on AutoMax Processors have access to the UDC dual port registers but that UDC tasks can only access those common variables that represent registers in their own dual port memory Task coordination between the UDC module and the AutoMax Processor is generally handled through periodic hardware interrupts generated by the UDC module AutoMax task needs to define a hardware event that will trigger some action by an AutoMax task using the BASIC statement EVENT The EVENT statement must reference the hardware interrupt status and control register ISCR register 2000 in the UDC dual port memory Although the UDC operating system itself actually causes the interrupt a task in the rack AutoMax or UDC must write to the scans per update register in the UDC dual port register 2001 in order to define the number of UDC task scans between updates of the the Nth scan application registers 1300 1599 and between hardware interrupts See figure 3 2 for more information Note that the register values being latched on every Nth scan provide a consistent context for evaluation of Control Block statements but that BASIC statements in UDC tasks read and write data immediately that is they
18. CCLK Communication Synchronization Error bit is set if two UDC CCLK ticks occur and no message is received from the PMI Bit 9 Hex Value 0200H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Multiplexed Data Verification Failure bit is set if data multiplexed into command feedback messages does not verify Bit 12 Hex Value 1 OOOH Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Invalid PMI Start Operating System Address bit is set by the PMI if the operating system is not within the allocated operating system address area This condition will cause the load ing of the PMI operating system to fail however the UDC module and the PMI will continue to retry loading the PMI operating system 3 11 084 A B Status Register Continued Bit 13 Hex Value 2000H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Insufficient PMI Memory to Load the PMI Operating System bit is set by the PMI if there is insufficient memory for loading the operating system This condition will cause the loading of the PMI operating system to fail however the UDC module and the PMI will continue to retry loading the PMI operating system Bit 14 Hex Value 4000H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Invalid PMI Load Ad
19. Control 4 1 4 1 AutoMaxTasks sssssssssssssss mr n 4 1 4 2 UDCTaskS u D rare e I e E OU ERA Rob DP oe RR ken eae 4 1 4 2 1 Typical Structure of a UDC Task 43 4 2 2 Local Tunable Variables 00 ccc ce cece ence ete nennen nen 4 5 4 2 2 1 Calculating Local Tunable Values 4 5 4 2 3 UDC PMITaskCommunication 0 tees 4 6 4 3 AutoMax Processor Task and UDC Task Coordination 4 9 5 0 On Line Operation nuria aida ad d RE ewes 5 l 5 1 Loading the UDC Module s Operating System 5 5 2 Loading the Drive Parameters and UDC Tasks 5 5 3 Running Stopping and Deleting UDC Application Tasks 5 2 5 4 UDC Information Log and Error Log scii Lei crios ass nesses aaa ra e tenes EIRRUE 5 2 Appendices Appendix A SD3000 Drive Register Reference Appendix B SD3000 Local Tunable Variables Appendix C SD3000 Control JAlgorllFim uin x RE _ _ ________ SD3000 Armature Current Regulation Algorithm SD3000 Field Current Regulation Algorithm Appendix D Status of Data in the AutoMax Rack after a STOP ALL Command or STOP ALL Fault Appendix E Power Module Model Numbers and Parameter Default Values Appendix F Armature Curre
20. DAMAGE TO EQUIPMENT AND BODILY INJURY The Rack Configurator application in the AutoMax Programming Executive is used to configure the modules in a rack Using the Rack Configurator you create a graphical representation of the actual modules in the rack Refer to of the AutoMax Programming Executive instruction manual for more information on configuring racks You can access the Rack Configurator by selecting the Configure Rack option from the Rack menu of the System Configurator An empty AutoMax rack will be displayed initially 1 1 Adding a UDC Module The UDC module may be placed in any slot in an AutoMax rack that contains at least one AutoMax Processor module M N 57C430A 57C431 or 57C435 Note that the UDC module cannot be used in a remote l O rack The rack does not require a Common Memory module M N 57C413 or 576423 unless more than one AutoMax Processor is being used A rack may contain up to ten UDC modules Some AutoMax modules e g the Common Memory module and the Ethernet Interface module may have an effect on the slot allocation in the rack that limits where other modules may be inserted Refer to the appropriate instruction manual for additional information A UDC module may also be placed in a rack containing a set of the AutoMax drive controller modules B M 57401 57405 57406 and 57408 Use the following procedure to add a UDC module to a rack Step 1 Select an empty slot in the rack Step 2 Select Add fro
21. The Monitor function in the Programming Executive allows all local tunables to be modified on line within the limits defined in the LOCAL statement in the UDC task Note that this is not recommended for the resolver calibration values because these values can be generated more precisely by the PMI during auto tuning At the end of the UDC task scan the new values are sent to the PMI to be used in the execution of the control algorithm 4 5 4 6 3 Enter the desired value into the CURRENT field for each LOCAL statement The programmer can choose to enter the desired values for any local tunables in the CURRENT field of the corresponding LOCAL statement or leave them unchanged 4 2 3 UDC PMI Task Communication Coordination between the two PMIs running their respective PMI tasks drives A and B and the UDC module running the corresponding UDC tasks is managed through the command and feedback messages sent over the fiber optic link The programmer does not control the operating system on the PMI The timing of the PMI is based on the regulator selected command message is sent to the PMI by the UDC module at the end of every scan of the UDC task Each message contains the data in registers 100 106 1 100 1106 rail data and the values of the pre defined local tunables that have changed Note that some data may be sent over the course of several command messages A feedback message is sent to the UDC module by the PMI immediately bef
22. above 12096 of the A C line voltage you will not be able to achieve full motor speed e Amps There is no default value This is the full load current that will be generated by the armature Power Module when the current reference specified by the UDC application task is equal to 10096 This value can range from 0 1 to 999 9 amps or 1000 to 8000 amps This value must be less than or equal to the Power Module s D C Amps values Refer to Appendix F for additional information on the relationship between the CT turns ratio and the armature current feedback resolution Note that if the current is less than 1000A the current may be entered in tenths of an ampere If the current is greater than IOOOA it may be entered in amperes This current value is used to adjust the programmable gain amplifier in the D C Power Technology module and the instanteous overcurrent IOC trip point threshold values Refer to Appendix for more information This value is also used to calculate the IR DROP e Max Current Limit 96 This is the maximum value in percent of the Amps value that may be used for current reference This current value is used to adjust the programmable gain amplifier in the D C Power Technology module and the JOC threshold values Refer to Appendix for more information 2 5 This value is also used to scale the current feedback and may range from 100 to 40096 The maximum amps produced by the Power Module can be calculated from the followin
23. counts e SCR SCR Diagnostic Decay Rate Default Current Value 99 Low Limit 1 High Limit 99 Step 1 The units are in counts e SCR DBAND SCR Diagnostic Deadband Default Current Value 10 Low Limit 0 High Limit 50 Step 1 The units are in percent e SCR TRIP SCR Diagnostic Trip Point Default Current Value 1500 Low Limit 1500 High Limit 3000 Step 1 The units are in counts Appendix B Continued The SCR diagnostic tunables are summarized below The first step in the diagnostics is to update a running average of the current feedback over the last 12 SCR firings The next step in the routine is to calculate the error as follows Running Average Current Feedback 100 E Pee Running Average If the calculated error is less than SCR_DBAND then the error is set to zero Higher values in SCR DBAND 6 can keep small errors from causing nuisance faults SCR_DBAND should be increased to reduce nuisance warnings that may occur due to small imbalances between the SCRs For example if SCR_DBAND is set to 20 all imbalances less than 20 are ignored To keep track of the error for every SCR there are 12 integrators only six would be used for non regenerative drive applications which are selected based on which SCR pair has just fired On every scan the integrators decay to zero using the following formula Integrator i Integrator i SCR_DECAY 100 SCR_DECAY cannot be less than one an
24. delay can range from 1 to 300 seconds 2 2 3 Speed Feedback Data Screen The Speed Feedback Data Screen allows you to enter specific information about the resolver or analog tachometer that is connected to the Resolver amp Drive l O module in the PMI rack and that is to be monitored for overspeed and tach loss conditions See figures 2 4 to 2 6 Note that if you choose No Speed Feedback the overspeed and tach loss functions will be disabled THE USER MUST ENSURE THAT THE CORRECT FEEDBACK TYPE HAS BEEN SELECTED DURING CONFIGURATION IF NO SPEED FEEDBACK HAS BEEN SELECTED THE USER MUST PROVIDE AN INDEPENDENT METHOD OF OF DETECTING OVERSPEED OTHERWISE A FEEDBACK LOSS WILL NOT BE DETECTED RESULTING IN MOTOR OVERSPEED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURYAND IN DAMAGETO OR DESTRUCTION OF THE EQUIPMENT Slot 1 UDC Parameter Entry SD3000 6 Pulse Current UDC Drive Speed Feedback Type 8 Drive A O Drive B 8 No Speed Feedback O Resolver O Analog Tach View Armature Data Q Field PM Data Speed Safety Data Speed Feedback Data Motor Base Speed RPM O Meter Port Selection Over Speed Trip RPM Tach volts at Over Speed Trip Slot 2 UDC Parameter Entry SD3000 6 Pulse Current UDC Drive 9 Drive A O Drive B View Speed Feedback Type O No Speed Feedback 8 Resolver O Analog Tach Armature PM Da
25. displayed value is equal to the number of amps times 100 For example 10 00 amps of field current would be displayed as 1000 The current is measured to within a tenth of an amp 213 1 213 Field Voltage Feed back Register Hex Value N A Var Name FLD_VFB DC Volts Range 32768 to 32767 Access Read Only UDC Error Code N A LED N A Description The Field Voltage Feedback register displays the field voltage feedback value A value of 1 is equal to 1 volt This voltage is calculated based on the AC line and field firing angle 214 1 214 User Analog input Register Hex Value N A Var Name Al Range 2048 10V to 2047 10V Access Read Only UDC Error Code N A LED N A Description The User Analog Input register displays the measured user analog input value from the Resolver Feedback connector on the Resolver amp Drive O module This value may be accessed through the PMI meter ports 2151 215 Resolver Scan Position Register Hex Value N A Var Name RES_SCN_POS Range 32768 to 32767 corresponding to the resolver s position Access Read Only UDC Error Code N A LED N A Description The Resolver Scan Position register displays the electrical position of the resolver if used at the beginning of the UDC task scan This register is reset to zero at power up 216 1 216 Resolver Strobe Position Register Hex Value N A Sug Var Name RES STR POS 6 Range 32768 to 32767 co
26. do to avoid this problem Data Acquisition Current feedback is measured by a pair of current transformers CTs located in the Power Module The D C Power Technology Module rectifies this signal and measures the voltage drop across a 10 2 ohm burden resistor The value of this burden resister may not be changed therefore to compensate for this inflexibility a programmable gain amplifier PGA is used to scale the voltage across the burden resister The scaled voltage is then applied to a voltage to frequency converter V F that produces a range of 0 to 2 MHz The output of the V F increments a counter at the rate of the frequency produced The number of counts is accumulated from SCR firing to SCR firing to provide a time averaged current signal Valid Gain Test The programming terminal software calculates the gain value that will be written to the PGA The gain depends on three parameters entered during configuration the current transformer s turn ratio the full load current and the maximum current limit It is calculated by the following formula Gain CT 255 10 2 I full 75 where CT current transformer turns ratio 255 maximum gain allowed 10 2 burden resister value full full load current limit maximum current limit 7596 over current limit The amount of gain is limited to a range of 26 to 255 A gain of less than 26 will not be accepted and the user will be required to change the value of on
27. error code 958 into the error log for the task The local tunable values can be modified through the application task on the UDC module and by the operator using the Monitor function See the BASIC language instruction manual J 3675 for more information on local tunable variables and the WRITE TUNE statement Local tunable variables cannot be forced Like all tunable values in the AutoMax environment the values of these UDC task tunables are retained through a power loss Note that the programmer can also define other local tunable variables for application specific purposes but that the total number of all local tunables in a UDC task cannot exceed 127 Calculating Local Tunable Values Depending upon the type of local tunable variable the CURRENT value e the value to be used for the next scan of the PMI can be determined in one of the following ways 1 Self tune The programmer can request the PMI to generate the values for some of the variables For example the programmer can set the resolver calibration command bit in register 101 A 101 to cause the PMI to adjust the resolver balance When the PMI has generated the values it sends them to the UDC module over the fiber optic link The UDC module stores the values in the corresponding tunable variables A copy of these values is maintained in the PMI for use in the execution of the control algorithm 2 Tune values from the Programming Executive software and tasks
28. forward or reverse To test the reverse bridge set bit 3 WARNING THE PROGRAMMER MUST WRITE THE FIRING ANGLE VALUE INTO THE ARMATURE TEST ANGLE REGISTER 102 1102 BEFORE ENABLING THE ARMATURE ALPHA TEST THE ACTUAL MOTOR ARMATURE MUST NOT BE IN THE CIRCUF UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY 3 14 1004 100 Drive Control Register Continued Bit 3 Hex Value 0008H Sug Var Name CML_ATRO Range N A Access Read Write UDC Error Code N A LED N A Description The Armature Alpha Test Reverse bit is set to select the reverse bridge for the armature alpha test Note that bit 2 must also be set to enable the test The firing angle value is entered into the Armature Test Angle register 1021 102 CML_ALPHA If this bit is not set the forward bridge will be tested This bit must be set before bit 2 and may not be changed while bit 2 is set Bit 4 Hex Value 001 OH Sug Var Name FML RUNG Range N A Access Read Write UDC Error Code N A LED N A Description The Field Regulator Run bit is set to enable the PMI Processor to begin executing the field regulation loop Bit 5 Hex Value 0020H Sug Var FML_ID Range N A Access Read Write UDC Error Code N A LED N A Description The Enable Field ldentification Test bit is set to start the test in which the resistance and time constant of t
29. is set and reset to clear the Drive Fault register 202 1 202 After a drive fault is latched the Drive Fault register must be cleared before the drive can be re started First any command bits that have been set in the Drive Control register 100 1 100 must be turned off Once the cause of the fault has been corrected the Fault Reset bit must be turned on and then off again The Fault Reset bit will clear the entire Drive Fault register Then the desired command bits may be turned on again The Fault Reset bit is edge sensitive i e leaving it set will not clear the Drive Fault register continu ously Note that if the fault condition still exists after register 202 1 202 is cleared it will continue to trigger drive faults until the problem has been corrected Bit 9 Hex Value 0200H Var Name WRN_RSTO Range N A Access Read Write UDC Error Code N A LED N A Description The Warning Reset bit is set and reset to clear the Drive Warning register 203 1 203 This bit is edge sensitive i e leaving it on will not clear the warning register continuously The Inter lock register 205 1205 is also cleared by setting and then resetting the Warning Reset bit Bit 11 Hex Value 0800H Var Name NO_FLDW Range N A Access Read Write UDC Error Code N A LED N A Description Automatic field weakening defaults to being on When field weakening is enabled and the CEMF value is greater than the motor voltage minus t
30. running if the UDC task is not running This bit must NOT be written to by the user This is a status bit that is written to by the operating system 101 101 W O Control Reglster This register contains the bits that control resolver strobe operation and the operation of the M contactor Bit 1 Hex Value 0002H Var Name MCRO Range N A Access Read Write UDC Error Code N A LED N A Description The M_Contactor Output bit is set to close the M contactor This bit is level sensitive Depending on whether the M contactor is switching A C or D C power specified when configuring the drive parameters this bit is controlled by the PMI Processor or the application program In either case the run permissive input on the Resolver amp Drive I O module must be on to turn on MCR If an A C contactor has been specified during parameter entry this bit is not controlled by the PMI Processor and MUST be set or reset by the programmer If a D C contactor is used to control power to the motor from the Power Module the contactor is con trolled by the PMI Processor In this case setting and clearing the MCR bit in application tasks has no effect on the M contactor output This bit is not a status bit and does not reflect the actual status of the M contactor The application program can use the M contactor feedback bit register 201 1 201 bit 1 to determine the status of the M contactor If you use both an A C and D C M contac
31. set if the USC does not report an End of Frame condition when the receive interrupt is generated Bit 2 Hex Value 0004H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The CRC Framing Error bit is set when the USC reports a CRC or Framing error on the last frame message received Bit 3 Hex Value 0008H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Overrun Error bit is set when the USC reports a receive first in first out overrun Bit 4 Hex Value 001 OH Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The DMA Format Error bit is set if the length of the received message does not match the length encoded in the message itself 84 1 084 PMI A B Status Register Continued Bit 5 Hex Value 0020H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Transmitter Underrun bit is set when the USC reports a transmit first in first out underrun Bit 6 Hex Value 0040H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The CCLK Communication Synchronization Error bit is set when two or more CCLK counter ticks occur and no message is received Bit 8 Hex Value 01 OOH Sug Var Name N A Range N A Access Read only UDC Error Code LED N A Description The UDC
32. the utilization of the CPU resources in the UDC module and various memory and PMI rack statistics Select U from the Info Log menu to display the information log Note that the UDC module s CPU utilization should not exceed 75 Like AutoMax tasks UDC tasks can also access the error log by using the BASIC statement CLR ERRLOG BASIC function TST ERRLOGQ The error log will display the first second and last errors and will maintain them until power is cycled Appendix SD3000 Drive Register Reference REGISTER MAP Registers Function 0 23 Rail port registers 24 79 System Use Only 80 89 UDC PMI comm 90 99 System Use Only 100 1 06 107 1 99 200 216 217299 System Use Only 300599 Application registers updated every scan for drives A and B 600 999 System Use Only 1000 UDC module test switch 1001 1 017 UDC module meter port setup registers 101 El 079 System Use Only 1060 1 069 UDC PMI comm status registers for drive B 1090 1099 System Use Only Command registers for drive A System Use Only Feedback registers for drive A register 1100 1 106 Command registers for drive B 11074 199 System Use Only 1200 216 Feedback registers for drive B 12174 299 System Use Only 1300 1 599 Application registers updated every Nth scan for drives A and B 16004 999 System Use Only 2000 2010 Interrupt Status and Control drives A and B 201 2047 System Use Only registers for REGISTER BIT DESCRIPTIONS R
33. will not perform the Tach Loss and Over Speed Diagnostics You must provide an independent method of detecting motor overspeed Note also that automatic field weakening will be disabled if you select No Speed Feedback Refer to register 100 1 00 bit 11 for more information Note that when a speed feedback device is used overspeed detection is active during auto tuning e Resolver If you select Resolver you must enter the Resolver Type e Analog Tach If you select Analog Tach you must enter the Tach Volts at Overspeed Trip Point 2 9 Speed Safety Data Selections Motor Base Speed RPM Enter the motor s base speed This value is the motor s top operating speed under full field and is the speed when field weakening begins This value is found on the motor s nameplate and can range from 0 to 3600 RPM Over Speed Trip RPM Enter the overspeed trip point This is the limit to be used for overspeed detection and can range from 0 to 5000 RPM When an analog tachometer is used this value is used to scale the analog voltage into RPM A typical value is 11096 of gear in speed e Tach Volts at Over Speed Trip Enter the tachometer voltage that will be present when the motor is turning at the overspeed trip point RPM Enter the value as x xx The value can range from 5 to 9 75 volts Resolver T lection e None Select this option if a resolver is not being used X1 X2 X5 If a resolver is being used select which type it is e
34. you can configure in each view e The Rail I O Port 0 and Port 1 views are used to configure the registers assigned to the hardware that is attached to the PMI Rail ports These registers can also be accessed by double clicking the PMI view The Command Registers view is used to configure pre defined drive control registers that are written to either by an AutoMax application task or by a UDC application task and then sent to the PMI e The Feedback Registers view is used to configure the feedback registers that display the current status of the drive These registers are written to by the PMI e The Application Registers Updated Every Scan view is used to configure the application registers that are used for the passing of application specific control and status data between an AutoMax Processor and the UDC module on every scan This register range is shared by drive A and drive B 3 1 Port 1 Drive A 6 11 Drive 18 23 Command Registers Drive A 100 106 Drive B 1100 1106 The Application Registers Updated Every Nth Scan view is used to configure the application registers that are used for the passing of application specific control and status data between an AutoMax Processor and the UDC module on every Nth scan where N is defined in register 2001 This register range is shared by drive A and drive B e The UDC Module Test I O Register view is used to configure the register that displays the status of the UDC module s
35. 080 1 089 UDC PMI communication status registers for drive B monitor only 1090 1 099 System Use Only 1100 1106 Command registers for drive B 1107 1199 System Use Only 201 12047 3 4 31 Rail O Port Registers Registers O 23 The Rail I O Port 0 and Port 1 views are used to assign variable names to the rail ports on the PMI If you have no hardware attached to these ports you do not configure these registers All of the Rail data for PMI A and PMI Bis combined into one section of the dual port memory Refer to Table 3 3 Note that the usage of each register is a function of what type of Rail is configured After a Stop All outputs are reset to zero and inputs continue to be updated The appropriate variable configuration screen will be displayed based on the hardware that you have specified is connected to the port The following types of hardware can be connected to these ports The instruction manual for the hardware shown is in parentheses M N 45C001 Digital I O Rail J 3012 M N 456630 4 Decade Thumbwheel Switch Input Module J 3654 e M N 45C631 4 Digit LED Output Module J 3655 M N SIC345 4 Analog Current Input Rail J 3689 M N 61C346 4 Channel Analog Voltage Input Rail J 3688 M N 61C350 2 Channel Analog Voltage Input Output Rail J 3672 M N 61C351 2 Channel Analog Current Input Output Rail J 3673 M N 616365 4 Channel Analog Current Output Rail J 3694 M N 616366 4 Channel Analog Volta
36. 1 When the value in RES_GAN is equal to zero the gain tuning procedure is performed automatically by the operating system The default CURRENT value is 0 The value ranges from O 255 counts with 1 count representing 1 5 volts of gain It is recommended that this value be generated using the auto tuning procedure because the PMI Processor can take into account the entire resolver circuit when setting the proper gain value If the value is adjusted too low a drive fault will be generated register 202 1202 bit 8 If the gain needs to be re calibrated reset the value of RES to zero However do not reset the value of RES_GAN to zero while the inner loop is running i e is set or a drive fault will be generated register 202 1 202 bit 8 RES BAL Resolver Balance Default Current Value 0 Low Limit 0 High Limit 79 Step 1 The RES_BAL local tunable contains the value of the resolver balance i e the amount of capacitance in pF that is to be added to the sine or cosine channel of the resolver to compensate for wiring Valid values are from 0 to 79 with 0 representing the fact that balance tuning has not been performed Values from 1 to 39 add capacitance to the cosine channel while values from 41 to 79 add capacitance to the sine channel Each integer value represents 100 pF as shown in figure Tuning Not Done 0 1 79 3900 pF 100 pF 0 pF 100 pF 3900 pF Added to Sine Channel Figure
37. 1041 104 Field test firing angle FML_ALBHA 1051 105 Field current reference FML_REF 1061 106 PMI D A output UDC_PMI_DA FEEDBACK REGISTERS A B 2001 200 Drive status Bit 0 CML On ONG 1 Armature ID test complete CML_IDC 2 Current minor loop in limit CML_LIM 3 Maximum firing angle reached 4 Field regulator on FML ONG 5 Field ID test complete FML_IDC 6 Field minor loop in limit FML_LIM 6 Fault detected FLT 9 Warning detected WFN 10 A C line phased ABC PH_ABC 11 Phase ready PH_RDY 14 CCLK synched PMI to UDC CCLI_OKO 15 PMI OS loaded PMI_OK 2011 201 NO status Bit 0 Run permissive input RPI 1 M contactor fdbk input M_FDBK 2 Invert fit status input INV_FLT or 115VAC aux Input 2 AUX_IN2 3 Power module air loss AIR_LOS or 11 5VAC aux input 3 AUX_IN3 4 Motor thermal switch M_THM or11 5VAC aux input 4 AUX IN4Q 5 11 5VAC aux input 5 AUX 6 Reslvr gain calib complete RES 7 Reslvr bal calib complete RES BALO 8 External strobe detected STR DETO 9 External strobe level STR_LVLO 202 1202 Drive fault Bii 0 Shorted SCR fault FLT_SCRO 3 A C line sync fault FLT_SYNO 4 Instantaneous over current FLT IOC 5 Conduction timeout fault CONG 6 Field loss fault FLT_FLD 7 Speed Feedback loss fault FLT_TAC 6 Resolver broken wire FLT_TBW 9 Resolver module fault FLT_RES 11 Power Technology fauft FLT_PTM 12 PMI power supply fault FLT_PS 13 PMI read write fault FLT_RW 14 UDC ru
38. 15 If the entire register is to be displayed enter a value of zero in the Bit Number register Step 3 Place the value maximum 32767 that will represent 1 OV in the Maximum Value register Step 4 Place the value minimum 32767 that will represent 1 OV in the Minimum Value register Step 5 Set register 1001 Initiate Change in Setup equal to a non zero value to store the new setup register configurations in memory The UDC module s meter ports are updated once per scan once the UDC task is running and CCLK is on They are updated every 5 milliseconds when CCLK is off UDC meter ports can also be set up on line using the Setup UDC selection from the Monitor menu as described in the AutoMax Programming Executive instruction manual This setup is valid only until there is a power cycle in which case the meter ports default to outputting zero voltage and the UDC Setup screen is cleared on power up Refer to the UDC Module instruction manual 5 3007 for more information about the UDC module s meter ports 3 6 2 1 Resolution of Meter Port Data For meter ports the output values will be clamped at the outside 1 0V limits Note that if you select to display a data range that is narrower than the actual range of the data your output values will not change until the value returns to within the range you selected to display In other words data is being updated at the rate described above but the actual output voltage may not c
39. 44 to be mapped to meter port 2 1007 UDC Module Meter Port 2 Bit Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Bit number of the UDC register specified in register 1006 that is to be mapped to port 2 Enter a value of 100 bit 00 to 115 bit 15 as required Enter a value of zero if all of the register s bits are to be displayed 1008 UDC Module Meter Port 2 Maximum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Set this register to the number that will represent 10V The maximum allowable value is 32767 1009 UDC Module Meter Port 2 Minimum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Set this register to the number that will represent 1 0V The minimum allowable value is 32768 3 45 3 46 Meter Port 3 1010 UDC Module Meter Port 3 Register Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description UDC register number 0 2044 to be mapped to meter port 3 1011 UDC Module Meter Port 3 Bit Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Bit number of the UDC register specified in register 1010 that is t
40. A Range N A Access Read only UDC Error Code N A LED N A Description The No Matching PMI Operating System Present bit is set if the correct PMI operating system is not present in the UDC module s operating system and the PMI is requesting an operating system This condition will cause the loading of the PMI operating system to fail however the UDC module and the PMI will continue to retry loading the PMI operating system UDC Module Ports A B Status Register Continued 80 1 080 UDC Module Ports Status Register Continued Bit 11 Hex Value 0800H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Invalid PMI Operating System Header bit is set if the UDC module cannot locate a valid PMI operating system header when attempting to load an operating system to a PMI This condition will cause the loading of the PMI operating system to fail however the UDC module and the PMI will continue to retry loading the PMI operating system Bit 12 Hex Value 1 OOOH Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Incompatible PMI Hardware bit is set if the PMI hardware is not compatible with the PMI operating systems in the UDC operating system 81 1 081 UDC Module Ports A B Receive Count Register Hex Value N A Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description This regis
41. AIL PORT REGISTERS A B 0 12 PMI port 0 channel 0 1 13 PMI port 0 channel 1 2 14 PMI port 0 channel 2 3 15 port 0 channel 3 4 16 PMI port 0 faults see below 5 17 PMI port 0 check bit fault counter 6 16 PMI port 1 channel 0 719 port 1 channel 1 8 20 PMI port 1 channel 2 9 21 PMI port 1 channel 3 10 22 PMI port 1 faults see below 11 23 PMI port 1 check bit fault counter Rail Fault Bits 0 Analog ch 0 input over range 1 Analog ch 0 input under range 2 Analog ch 1 input over range 3 Analog ch 1 input under range 4 Analog ch 2 input over range 5 Analog ch 2 input under range 6 Analog ch 3 input over range 7 Analog ch 3 input under range 6 No device plugged Into configured port 9 Bad ID code 10 Bad rail comm check bits received 11 Processor interface not ready status registers for drive A UDC PMI COMMUNICATION STATUS A B 6011060 UDC module status Bit O Invalid rcv interrupt 1 No end of frame status 2 CRC framing error 3 Overrun error 4DMA format error 5 Transmitter underrun 6 CCLK comm synch error 7 External Loopback data error 6 Missed gains 9 Multiplexed data verification failure 10 No matching PMI OS 11 Invalid PMI OS header 12 Incompatible PMI H W UDC module good msg recvd count UDC module CRC error count UDC module format error count PMI port status Bit O Invalid rcv interrupt 1 No end of frame status 2 CRC framing error 3 O
42. B 1 Capacitance Used for Resolver Balancing B 3 B 4 Appendix B Continued Open SCR Diagnostic Variables The open SCR diagnostics are used to make certain that all SCRs in the Power Module are on the average carrying the same load The current flow through each SCR is compared to the average current being supplied by the Power Module If an SCR is not carrying its share of the load that SCR or SCR pair in the case of a regenerative drive will be identified in register 204 1204 and a warning will be reported in register 203 1 203 This diagnostic is run by the PMI Processor operating system every time an SCR is fired SCR diagnostic failures are usually due to broken wires faulty SCRs or faulty gate drivers in the Power Module However the diagnostic routines may need to be adjusted due to unbalanced A C line voltages or unusual operating conditions In this case the programmer may need to adjust the tunable gain values used in the diagnostic routines in order to make the system more tolerant of unusual conditions that are found in the application The SCR diagnostic tunable values listed below determine the level of error reporting that will occur If the default CURRENT values are not acceptable the programmer must either change them or tune them on line The STEP parameter for all the variables is always 1 one e SCR GAN SCR Diagnostic Gain Default Current Value 100 Low Limit 1 High Limit 500 Step 1 The units are in
43. Block Language e J 3677 AutoMax Ladder Logic Language e J 3688 4 Channel Analog Voltage Input Rail e J 3689 4 Channel Analog Current Input Rail e J 3694 4 Channel Analog Current Output Rail e J 3695 4 Channel Analog Voltage Output Rail e S 3005 Distributed Power System Overview 1 1 S 3007 S 3008 S 3009 S 3010 S 3011 S 3012 J2 3078 Distributed Power System Universal Drive Controller Module Distributed Power System SD3000 Power Module Interface Rack Distributed Power System Fiber Optic Cabling Distributed Power System SD3000 Power Modules Distributed Power System SD3000 Diagnostics Troubleshooting and Startup Guidelines Distributed Power System SD3000 Information Guide AutoMax Programming Executive Version 3 5 2 0 CONFIGURING THE UDC MODULE REGULATOR TYPE AND PARAMETERS DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL AND OTHER APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE ONLY QUALIFIED RELIANCE PERSONNEL OR OTHER TRAINED PERSONNEL WHO UNDERSTAND THE POTENTIAL HAZARDS INVOLVED MAY MAKE MODIFICATIONS TO THE RACK CONFIGURATION ANY MODIFICATIONS MAY RESULT IN UNCONTROLLED MACHINE OPERATION FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
44. C Drives Power Module Interface Rack instruction manual 5 3008 for additional resolver calibration information Bit 8 Hex Value 01 OOH Var Name STR_ENAO Range N A Access Read Write UDC Error Code N A LED N A Description The Enable External Strobe bit is set to enable the external strobe on the resolver to capture the position of the resolver when the rising edge of the external strobe is detected As long as this bit is set the external strobe is enabled If this bit is set in conjunction with bit 9 the resolver position is captured on both the rising and falling edges of the input signal See register 201 1 201 bits 8 and 9 for additional information The resolver position data is placed in the Resolver Strobe Position register register 216 1 216 Bit 9 Hex Value 0200H Sug Var Name STR ENF Range N A Access Read Write UDC Error Code N A LED N A Description The Enable External Strobe Falling Edge bit is set to enable the external strobe on the resolver to capture the position of the resolver when the falling edge of the external strobe is detected As long as this bit is set the external strobe is enabled If this bit is set in conjunction with bit 8 the resolver position is captured on both the rising and falling edges of the input signal See register 201 A 201 bits 8 and 9 for additional information The resolver position data is placed in the Resolver Strobe Position register register 216
45. Configuration Views and Registers 3 2 Table 3 2 UDC Module Dual Port Memory Register Organization 3 8 VO Register 2442452 Er Ch S dns ben ctn ta E Rn heh a deste ds 34 Table 3 4 Fault Register and Check Bit Fault Counter Register Usage for a Digital O Rail or 4 Output Analog Rail 3 5 Table 3 5 Fault Register and Check Fault Counter Register Usage for 4 Input Analog Rail Module e 3 5 Table 3 6 Fault Register and Check Bit Fault Counter Register Usage for a 2 Output 2 Input Analog Rail Module 3 6 Table 3 7 UDC Module Meter Port Setup 3 42 1 0 INTRODUCTION 11 The products described in this manual are manufactured or distributed by Reliance Electric Industrial Company Distributed Power System DPS drives are controlled through coordination between e Tasks written by the programmer for the AutoMax Processor e Tasks written by the programmer for the Universal Drive Controller UDC module The control and a number of software routines executed by the Power Module Interface PMI The data and commands required by the PMI operating system to carry out its functions are provided by the programmer through the AutoMax rack configuration and the UDC ta
46. D BITS MAY RESULT IN IMPROPER SYSTEM OPERATION FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY CAUTION Electronic motor overload protection must be provided for each motor in a Distributed Power drive application to protect the motor against excessive heat caused by high currents This protection can be provided by either the THERMAL OVERLOAD software block or an external hardware device Applications in which a single power module is controlling multiple motors cannot use the THERMAL OVERLOAD software block and must use an external hardware device or devices to provide this protection Failure to observe this precaution could result in damage to or destruction of the equipment EthernetTM is a trademark of Xerox Corporation WindowsTM is a trademark of Microsoft Corporation ReSourceTM is a trademark of Reliance Electric Company or its subsidiaries Reliance and AutoMax are registered trademarks of Reliance Electric Company its subsidiaries Copyright Reliance Electric Industrial Company 1995 Table of Contents 10 Introduction MIS 1 1 1 1 Related Publications 1 1 2 0 Configuring the UDC Module Regulator Type and Parameters 2 1 24 Adding UDG Modules atem We ocu qe vu eeu ds 2 1 2 1 1 Rules for Configuring Selecting Drives for the UDC Module 2 2 2 2 Entering the Drive Parameters nee nennen ernennen nern nen 2 2 2 2 1 Armat
47. Distributed Power System SD3000 Drive Configuration and Programming Instruction Manual 5 3006 1 CE RELIAN TRIC ICI LEC The information in the users manual is subject to change without notice DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL AND OTHER APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE THE USER MUST PROVIDE AN EXTERNAL HARDWIRED EMERGENCY STOP CIRCUIT OUTSIDE OF THE CONTROLLER CIRCUITRY THIS CIRCUIT MUST DISABLE THE SYSTEM IN CASE OF IMPROPER OPERATION UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY WARNING ONLY QUALIFIED RELIANCE PERSONNEL OR OTHER TRAINED PERSONNEL WHO UNDERSTAND THE POTENTIAL HAZARDS INVOLVED MAY MAKE MODIFICATIONS TO THE RACK CONFIGURATION VARIABLE CONFIGURATION AND APPLICATION TASKS ANY MODIFICATIONS MAY RESULT IN UNCONTROLLED MACHINE OPERATION FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN DAMAGE TO EQUIPMENT AND BODILY INJURY WARNING REGISTERS AND BITS IN THE UDC MODULE THAT ARE DESCRIBED AS READ ONLY OR FOR SYSTEM USE ONLY MUST NOT BE WRITTEN TO BY THE USER WRITING TO THESE REGISTERS AN
48. ED N A Description This register contains the number of messages with format errors received by the Drive A and Drive B 88 1 UDC Module Potts A B Fiber Optic Link Status Register Hex Value N A Name Range N A Access Read only UDC Error Code N A LED N A Description This register indicates the current operating state of fiber optic links A and B The lower byte bits O 7 indicates the actual link status while the upper byte bits 8 15 shows whether the communication taking place is synchronized or not If the lower byte is equal to xx01 H the UDC module is waiting for a request from the PMI for an operating system If the lower byte is equal to xx02H the UDC module is downloading an operating system to the PMI If the lower byte is equal to xx03H the UDC module and the PMI are exchanging data If the lower byte is equal to xx06H the external loopback test is being conducted on the fiber optic link If the upper byte is equal to 01xxH the communication between the UDC module and the PMI is synchronized If the upper byte is equal to 02xxH the communication between the UDC module and the PMI is unsynchronized 89 1089 UDC Module Ports A B Transmitted Message Count Register Hex Value N A Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description This register contains the number of messages transmitted by the UDC module on Port
49. F THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL AND OTHER APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE WARNING ONLY QUALIFIED RELIANCE PERSONNEL OR OTHER TRAINED PERSONNEL WHO UNDERSTAND THE POTENTIAL HAZARDS INVOLVED MAY MAKE MODIFICATIONS TO THE APPLICATION TASKS ANY MODIFICATIONS MAY RESULT IN UNCONTROLLED MACHINE OPERATION FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN DAMAGE TO EQUIPMENT AND BODILY INJURY Distributed Power Drive products are sold only as part of engineered systems The application programming required for each engineered system is developed in response to each customer s specifications Information in this chapter is general enough to apply to most engineered systems however implementation details may vary Always refer to your wiring diagrams for specific information about your engineered system 4 1 AutoMax Tasks AutoMax tasks are used to implement safety interlocks coordinate multiple UDCs and collect data from UDC modules in the rack They can access all common memory 1 0 in the AutoMax rack including the dual port memory in the UDC module AutoMax drive control tasks are generally written in PC Ladder Logic language Typically these tasks control the Drive Control register 100 1100 and the I O Control regi
50. Field Weakening Turned Off Field Current Regulation Algorithm FML RUNG FML FML ONG Sequence FML_FB FLD 1 MIN FML_REF Amie SCR Module CML_WCO FLD_R FLD_TE FLD HOT AC VRMS 6 Refer to register 100 1 100 bit 11 in chapter 3 for additional information H4 Appendix I Instantaneous Overcurrent Trip Point The instantaneous overcurrent IOC trip point is a function of the maximum current limit value and the motor s armature current as shown in the following equation IOC Trip Point Armature Amps x Max Current Limit 75 When the maximum current limit value is equal to 150 the upper limit of the IOC trip point is set at 225 of the motor s armature current value The parameter entry screen will display an error message if the IOC trip point is greater than 225 of the Power Module s D C Amps current rating Refer to section 4 2 1 of this manual for more information Appendix D C Amp Rating Parameter Precautions Normally the D C Amp rating parameter is automatically filled in by the system after the user selects a Power Module part number from the list However if you are filling in your own values because you are using a Power Module that is not on the list you must take the following precaution when filling in the D C Amp rating parameter Because of internal design considerations the following four D C Amp ratings are interpreted by the PMI operating sys
51. Interrupt line ID 2 Interrupt allocated 4 Interrupt this scan 5 CCLK counting 6 Enable CCLK to backplane 7 Interrupt enabled 15 Interrupt status 2001 Scans interrupt 2002 SPI counter 2010 Diagnostic error code Bit 0 UDC memory failure Only bit 6 in register 2000 can be written to by the programmer All other bits in register 2000 are read only GAIN VARIABLES Current minor loop crossover frequency CML_WCO initial 200 radians Armature resistance ARM R 1000 1 Ohm Armature field electrical time constant ARM TE 10 1 msec Te Armature threshold current ARM_CCT 10 1 amp Field minor loop crossover FML_WCO frequency initialzi 5 radians Field resistance FLD_R 10 1 Ohm Field electrical time constant FLD TE 1 1 msec Tf SCR diagnostic gain SCR GAN initial 100 SCR diagnostic decay rate SCR_DECAY initial 99 SCR diagnostic deadband SCR_DBAND initial 10 SCR diagnostic trip point SCR_TRIP initial 1500 Resolver gain RES_GAN initial 0 Resolver balance RES_BAL initial 0 that the scale and initial values shown for these variables apply to 3 phase armature regulation and I phase field regulation Appendix B SD3000 Local Tunable Variables Armature and Field Gain Variables With the exception of armature and field crossover frequency armature and field current gain variable values can be generated automatically by using the ar
52. NIFICANT AND MOST SIGNIFICANT 16 BITS HAVE BEEN TRANSMITTED BEFORE THEY ARE READ BY THE RECEIVING APPLICATION PROGRAM FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY OR DAMAGE TO EQUIPMENT E UDC Scan L Latch every scan registers that are inputs to task B Write every scan registers that outputs from task A 5 S x 3 3 U INd Latch every scan Write every scan m registers that registers that are inputs to task A outputs from task B Task B can act on Task A outputs within a scan Figure 3 1 Typical UDC Task Scan Note that the same bits or registers must not be written to and used as outputs by both an AutoMax task and a UDC task Application registers 1300 1 599 can be used every Nth scan of the UDC task Nth scan registers should be used when it is necessary to synchronize one or more UDC tasks to an AutoMax task The registers within this range 13004599 that are written to by a UDC task are updated by the UDC operating system from its local memory to dual port memory at the end of the scan that occurs before the Nth scan N i At that time an interrupt will be generated by the UDC operating system to indicate that new data has been written to the dual port memory Refer to the 2000 series registers for more information on interrupts An AutoMax task must have defined a hardware EVENT in order to be ab
53. Nueos 1 0 25 EUROS 20205 ueog 805 guess zueos p ueog G 5 482 0 sind 81e yeu 51015 6 UBOS YOR sindino ampon San 8 N gt GEHE GANE ee ee QUAND ee ee l uruiooz ueos yn 9 Jed sueos 9 UES 3 39 Nth Scan Intenupts Figure 32 The following data types can be defined in the application register area boolean bit integer 16 bits double integer 32 bits and real 32 bits Because of the way in which read and write operations occur in the UDC dual port memory however the programmer must assign boolean variables carefully within pairs of 16 bit registers The UDC operating system generally operates on the amount of memory called for by the data type e g when it is requested to write to a 16 bit integer value it writes only to those specific 16 bits However in the case of boolean variables the UDC operating system always operates on 32 bits at a time It is not possible for the operating system to write to only one bit within a register The remaining 31 bits in the register pair will be written over as well possibly resulting in corrupted data Within any pair of 16 bit registers beginning on an even number boundary i e registers 300 and 301 302 and 303 but not registers 301 and 302 all boolean variables must b
54. Power Module s 100 output D C Amp rating The value can range from IA to the rated armature amperage 100 D C amp rating with a maximum of 8000A This value is found on the Power Module s nameplate and is used in the inverting fault avoidance algorithm All Reliance Power Module bridges have 150 rating for 1 minute See Appendix J for precautions on this parameter e CT Turns Ratio The CT turns ratio parameter defines the input to output ratio of the current transformer in the Armature Power Module The ratio is assumed to be This parameter is found on the Power Module s nameplate Refer to Appendix F for additional information on the relationship between the CT turns ratio and the armature current feedback resolution This parameter is also used to setup the D C Drive Technology module s programmable gain amplifier and to scale armature current feedback into amperes Refer to Appendix F for additional information on the relationship between the CT turns ratio and the armature current feedback resolution Motor Armature Rating Selections e Volts There is no default value The maximum value is the rated D C output voltage This value is found on the motors nameplate This voltage is used to calculate when field weakening begins Refer to register 100 1 100 bit 11 for more information The rated motor armature voltage must be no greater than the voltage rating of the Power Module or 12096 of the A C line voltage Note that if you go
55. Usage for a Digital Rail or 4 Output Analog Rail Module DriveA DriveB u n E Registers Registers Description 4 16 Port 0 Fault Register 22 Port 1 Fault Register Bit 8 No device plugged into a configured port Bit 9 Bad ID code device other than a rail is plugged into the port Bit 10 Bad rail communication check bits received Bit 11 PM interface is not ready 17 Port 0 Check Bit Fault Counter Register 11 23 Port 1 Check Bit Fault Counter Register The register can be reset by setting bit 9 of the Warning Reset register 100 1100 Table 3 5 Fault desa and Check Bit Fault Counter Register Usage for a 4 Input Analog Rail Module Port O Fault Register Port 1 Fault Register Bit 0 Analog Channel 0 Input Over Range Bit 1 Analog Channel O Input Under Range Bit 2 Analog Channel 1 Input Over Range Bit 3 Analog Channel 1 Input Under Range Bit 4 Analog Channel 2 Input Over Range Bit 5 Analog Channel 2 Input Under Range Bit 6 Analog Channel 3 Input Over Range Bit 7 Analog Channel 3 Input Under Range Bit 8 No device plugged into a configured port Bit 9 Bad ID code device other than a rail is plugged into the port Bit 10 Bad rail communication check bits received Bit 11 PMI interface 15 not ready Port O Check Bit Fault Counter Register Port 1 Check Bit Fault Counter Register The register can be reset by setting bit 9 of the Warning Reset register 100 1 100 Table 3 6 Fault Register and Check Faul
56. affected because their thermal time constants are on the order of minutes A value of 1 in this variable means that 1 100 of accumulated error will be carried over to the next calculation A value of 100 the default means that the gain is 1 100 1 00 A value of 500 the maximum means that the gain is 5 times the error 500 1 00 When Integrator i becomes greater than SCR_TRIP a diagnostic bit is set to indicate that a problem has been detected Making SCR_TRIP larger raises the detection threshold for errors SCR_TRIP determines the threshold of integrated error that will cause a warning to be annunciated The higher the value maximum 3000 the more tolerant the system will be of SCR errors The lower the value 1500 minimum and default the earlier the system will annunciate SCR errors B 5 Appendix SD3000 Control Algorithm Armature and field current regulation in SD3000 Drives is performed by the PMI Processor Application tasks on the UDC module and AutoMax Processor are used to intiate auto tuning run and stop the current regulation algorithms monitor the PMI Processor for warnings and faults and coordinate with higher level control tasks The PMI Processor operating system regulates armature and field current based on the results of auto tuning and on the configuration parameters entered by the programmer The PMI Processor calculates firing angle values for the D C Technology module which in turn provides the firing si
57. art of the task will only run on the initial scan of the task or on any subsequent restart 1 Local and common variable definitions This section of the task defines names for values internal to the task LOCALs and all UDC dual port memory registers used in the task COMMONS 2 Pm defined local tunable variable definitions This section defines the variables that are used by the PMI for functions such as tuning the control algorithm and calibrating the resolver The UDC task skeleton file in the Programming Executive software includes these local tunable definitions See section 4 2 2 and Appendix B for more information 3 Initialization a UDC Meter Port set up The registers whose values will be output on the UDC Meter Ports are defined here These registers can also be defined on line using the Programming Executive software optional b Scans per update definition The scans per update register 2001 for both drive A and B is defined to tell the UDC Processor when to update the Nth scan registers and optionally also when to interrupt an AutoMax Processor task that has defined a hardware EVENT tied to the UDC s interrupt register The AutoMax task can then read from and write to the UDC dual port memory registers on a deterministic basis and coordinate with the other tasks in the system optional c Any other initialization required for the application This portion of the task steps 1 3 before the SCAN LOOP block on
58. as a configuration parameter This bit is not used if the No Speed Feedback option is selected as a configuration parameter Bit 8 Hex Value 01 Sug Var Name FLT_TBW Range N A Access Read Only UDC Error Code 1008 LED FDBK OK on the Resolver 8 Drive I O module Description The Motor Speed Feedback Broken Wire Fault bit is set if a sine or cosine signal being used for speed or other application feedback is missing due to a broken wire or the resolver gain tunable RES _ set too low This bit is always tested if a resolver is used This bit is not set if No Speed Feedback is selected during parameter entry and register 101 1 101 bit 10 is set Refer to register 101 1 101 bit 10 for more information Bit 9 Hex Value 0200H Var Name FLT RESQ Range N A Access Read Only UDC Error Code 1009 LED N A Description The Resolver Fault bit is set when a blown fuse is detected on the Resolver amp Drive I O module 3 27 3 28 202 1 202 Drive Fault Register Continued Bit 10 Hex Value 0400H Sug Var FLT_OSP Range N A Access Read Only UDC Error Code 1010 LED EXT FLT on the PMI Processor module Description The Overspeed Fault bit is set when the motor s velocity exceeds the value entered as the Over Speed Trip RPM configuration parameter This bit is not used if the No Speed Feedback option is chosen as a configuration parameter Bit 11 Hex Value 0800H
59. asks to actually run allow some time for processing overhead and use the resulting value to determine the TICKS value for the SCAN LOOP block in both the drive A and drive B tasks The AutoMax Control Block Language manual J 3676 lists the execution times of the Control Blocks For example if the programmer assigns UDC task A a TICKS parameter of 8 4 ms then UDC task B must also have TICKS defined at 8 and both tasks must be able to execute within an 8 tick window of time or an overlap error will result and all tasks in the rack will stop If the tick rates do not match error code 956 will be reported for one or both tasks in the error log and all tasks in the rack will be stopped 4 3 4 4 Note that unlike Control Block tasks on AutoMax Processors UDC tasks cannot run on a hardware or software event basis The EVENT parameter cannot be specified in the SCAN LOOP block in UDC tasks This means that there is no timeout for execution of the UDC tasks If the UDC task is scanned to the SCAN LOOP block and CCLK is not on the task will simply wait without timing out Note that no other control blocks are permitted before the SCAN LOOP block BASIC statements however are permitted before the SCAN LOOP block 5 Other Control Block and BASIC statements or functions This portion of the task consists of the logic specifically required for the application This portion of the UDC task after the SCAN LOOP block is the only part of t
60. cess Read Only UDC Error Code N A LED N A Description The Field Regulator On bit set whenever the field regulator loop is executing enabled See register 100 1 100 bit 4 When the request for the function is turned off this bit will be turned off Bit 5 Hex Value 0020H Sug Var Name FML_IDC Range N A Access Read Only UDC Error Code N A LED N A Description The Field Identification Test Complete bit is set when the field identification test is fin ished See register 100 1 100 bit 5 When the request for the function is turned off this bit will be turned off Bit 6 Hex Value 0040H Sug Var Name FML_LIMB Range N A Access Read Only UDC Error Code N A LED N A Description The Field Minor Loop in Limit bit is set when the advance of the firing angle is being limited or the bridge is full on This bit is normally off Bit 8 Hex Value 01 00H Sug Var Name FLT Range N A Access Read Only UDC Error Code N A LED N A Description The Processor sets the Fault Detected bit when any fault is detected See Drive Fault register 202 1 202 It is reset by bit 8 of register 100 1 100 Bit 9 Hex Value 0200H Var Name WRNO Range N A Access Read Only UDC Error Code N A LED N A Description The Processor sets the Warning Detected bit when any warning is detected See Drive Warning register 203 1 203 It is reset by bit 9 of register 100 1 100
61. criptions are shown in the following format Register Number for Drive A B Register Name Bit The specific bit location where applicable Hex Value The hexadecimal equivalent of the bit number Range The upper and lower limits of the register value where applicable For bit descriptions this field will contain N A Access The level of access by the application task e g Read Write UDC Error Code A drive fault s corresponding error code This is reported in the log for the task in which the error occurred LED The corresponding faceplate LED where applicable Description A description of the register or bit Table 3 1 UDC Module Configuration Views and Registers Register Range Described in Section Application Registers Updated Every Scan 300 599 Application Registers Updated Every Nth Scan 1300 1599 UDC Module Test Register 1000 R Data Registers 2000 2002 2010 Feedback Registers Drive A 200 216 __ Drive B 1200 1216 36 Port 0 Drive A 0 5 Drive B 12 17 L 3 1 3 5 3 7 Table 3 2 UDC Module Dual Port Memory Register Organization Registers Function Rail O port registers 2479 System Use Only 80 89 UDC PMI communication status registers for drive A monitor only System Use Only 100 1 06 Command registers for drive A 107 1 99 System Use Only 200 216 Feedback registers for drive A 00 UDC module test switch register 1018 1 079 System Use Only 1
62. d should not be greater than 99 Making SCR_DECAY smaller makes the error decay faster SCR_DECAY indicates how much error is retained from calculation to calculation It should be decreased when nuisance warnings are occuring due to large cyclic loads During step changes in current some of the SCRs in the bridge will carry more or less current than the average until a steady state is achieved During these periods the error integrator will integrate in the positive direction even though there is no real current sharing problem SCR_DECAY can keep the error integrator from slowly integrating up to the warning point over time due to these transient conditions Entering a value of 99 would result in the error integrator being decreased by 1 of its value every time it is calculated for a particular SCR A value of 1 would result in the error integrator being decreased by 99 of its value On every scan the integrators build up by the following formula Integrator 1 Integrator Error SCR_GAIN 00 SCR_GAIN determines how fast error builds up The value should be increased if warnings need to be annunciated quickly for example in the case of a Power Module being run close to current or temperature limits The default setting 100 may result in the lapse of several seconds before the problem is recognized and annunciated Note that in most cases other SCRs in the bridge that must make up for the loss of one SCR will not be adversely
63. d to the UDC a UDC application task is included in the on line task list with the AutoMax Processor application tasks It can be run stopped monitored deleted in the same way as any other application task The priority field will be set to N A for UDC application tasks The task for drive A always executes first followed by the task for drive B The Run All command will run all AutoMax and UDC tasks The UDC module s tasks can be run whether or not the following conditions are met the PMI is communicating with the UDC module the PMI operating system has been loaded from the UDC module to the PMI which happens automatically when the PMI is connected to the UDC module Stopping UDC Tasks UDC applications tasks both tasks A and B together must run a least every 10 milliseconds Once the SCAN LOOP statement is executed the UDC module will cause a Stop All in the rack if the task does not complete its scan within 10 milliseconds Deleting UDC Tasks When a UDC application task is deleted any local variables which were forced are removed from the force table The task s error log is also cleared UDC Information Log and Error Log The information log and the error log for UDC task can be displayed by selecting I for Info Log from the ON LINE menu Refer to the AutoMax Programming Executive for the procedure The information log for a slot containing a UDC module will display the UDC operating system s part number
64. do not read from and write to a local buffer Referencing the same common values in both Control Block and BASIC statements in one task can result in errors 4 9 1 55200 XENONY ui 458 ou 8q eeu 1dnuejyui yan eseo si ul Jdruseju pue seyepdn Yan eu uj ULD ASE SIU se BUOJ 15 JOSS9204d xejoiny Aq eu uo SI 3109 g pue sysej ujoq oj s ndur ese yey sJejsiDeJ ueos og sjndino ere yey 105590014 Xeyyoyny 3dnuiejur S19 6160 UEOS QN OHM sejeJeuebD waysks Buneiedo Jan V s ndu se pesn sJejsiDe ueos ABAV YNET V xs8 sjndui eje yeu s eys e ueas Aena ejnpouu san woy sidnueyui Burovues ASEL J0sse2o1d XENONY y woy eje yey V Ase sindino ey 5 UBOS BJM 51615 UAG 8 358 0 syndui g ase o1 yeu 5 yey 56 81601 ueos 2 YAT Bid sindino ese yey 1561 ueos OM SISSI OIE OI OIR arameo 8 752 Jarno vera vind sung J amdu vecino vere Tyne _ Nueos 1 0 pueog gueog zueog ueog rusos gueos zueog 1 8 ueos
65. dress bit is set by the PMI if the address at which it is to load the operating system is invalid This condition will cause the loading of the PMI operating system to fail however the UDC module and the PMI will continue to retry loading the PMI operating system Bit 15 Hex Value 8000H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The PMI Operating System Overflow into Stack Memory bit is set by the PMI if the load ing of the PMI operating system will overrun the PMI stack memory area This condition will cause the loading of the PMI operating system to fail however the UDC module and the PMI will continue to retry loading the PMI operating system 85 1 085 PMI Receive Count Register Hex Value N A Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The PMI A B Receive Count register contains the number of messages received by the Drive A and Drive B PMls This is a 16 bit value that rolls over when it reaches its maximum 86 1 086 PMI CRC Error Count Register Hex Value N A Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description This register contains the number of messages with CRC errors received by the Drive A and Drive 87 1087 PMI A B Format Error Count Register Hex Value N A Sug Var Name N A Range N A Access Read only UDC Error Code N A L
66. drive parameters to the UDC module in a slot you specify or to all UDC modules in the rack When the drive parameters are loaded the AutoMax Programming Executive will determine if the drive parameters are compatible with the existing rack configuration If the drive parameters are not compatible an error message will be displayed on the personal computer You also have the option of loading UDC tasks to the UDC modules in the rack If you choose to load tasks the Programming Executive will display a list of all the AutoMax tasks and UDC tasks for the system Select the task you want to load from the list Remember that you must load the rack configuration and the drive parameters before loading UDC tasks to a UDC module Refer to the AutoMax Programming Executive instruction manual for the complete Load procedure 51 5 2 5 3 Running Stopping and Deleting UDC Application Tasks WARNING UNDERSTAND THE APPLICATION BEFORE STARTING A TASK OUTPUTS MAY CHANGE STATE RESULTING IN MACHINE MOVEMENT FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT THE APPLICATION PROCESS STOPS IN A SAFE MANNER WHEN THE APPLICATION TASKS STOP FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN BODILY INJURY 5 4 Running UDC Tasks A UDC application task is required in order to control a Distributed Power drive To control two drives two UDC tasks are required Once it is loade
67. drive tasks or by setting a bit in another module that can turn on CCLK Only one module in the rack must turn on CCLK Note that after a STOP ALL occurs in the rack CCLK will be disabled and must be re enabled again in order for UDC tasks to go into run See figure 4 2 for the typical data flow between the UDC module and the PMI To that communication between the UDC module and the PMI is resulting in up to date feedback data it is recommended that the drive s run permissive logic include the CCLK synchronized status bit register 200 1200 bit 14 the communication lost fault bit register 202 1202 bit 15 COM_FLTO as shown below COM FLTG RUN PERM pese A Start Permissive Logic Refer to the individual bit descriptions in this manual for more information 4 7 e g Aena uo suns puana eu o6sui ce z Alena au uo sums WD jua no ey pezluoJyou s jou ere pue 5452 DN peziuo1usu s si JOSSOIOIA pue DCN eu ueewjeq siejsiDe1 3oeqpee pue Jo uoneoiunuJuJo2 uo peuun ese pue 1ueuno uni Ind ueeq sse agn eur uod jenp ul s ays a pue 0J UOO 0 MOU SSJUM
68. dule air loss is being monitored this bit reflects the status of the Power Module s air loss signal An air flow sensor in the Power Module generates this signal When the signal is present this bit is on Bit 4 Hex Value 001 OH Sug Name AUX_IN4 or M Range N A Access Read Only UDC Error Code N A LED AUX on the Resolver amp Drive I O module Description The Auxiliary Input 4 bit reflects the status of 115 VAC auxiliary input 4 on the Resolver amp Drive I O module When the input signal is present this bit is on If the motor s thermal switch is being monitored this bit reflects the status of the switch s signal When the input signal is present this bit is on 201 201 WO Status Register Continued Bit 5 Hex Value 0020H Var Name AUX_IN5O Range N A Access Read Only UDC Error Code N A LED AUX IN5 on the Resolver amp Drive I O module Description The Auxiliary Input 5 bit reflects the status of 115 VAC auxiliary input 5 on the Resolver amp Drive l O module When the input signal is present this bit is on Bit 6 Hex Value 0040H Sug Var Name RES GANG Range N A Access Read Only UDC Error Code N A LED N A Description The Resolver Gain Calibrated bit is set when the resolver gain calibration procedure is completed This procedure is performed when the value stored in RES GAN 6 equals zero Bit 7 Hex Value 0080H Var Name RES BALO Ra
69. e S6 Drive Model Number KW D C Output Volts D C Output Amps CT Turms Ratio 3923 simum m mm mei _ 30303 TC 240 360 180 265 320 480 3860 1 30304 TC 480 720 360 535 500 640 960 7770 1 29676 7 420 1 200 31 0 895 500 560 1 600 10000 1 29676 9 1200 1 500 895 1 115 2000 10000 1 840 57 20 S61 500 1250 10500 1 575 VAC Line Voltage S6R Drive soszTE 018045185 600 85250 sosisTC 240360 080 265 S00 320400 38901 postete 480 720 260 55 600 T 77703 295767 4201200 310895 500 560 600 190003 1200 1500 895 1116 00 2000 100003 690 Line Voltage S6 Drive Model Number D C Output Volts D C Output Amps CT Tums Ratio 2761 0 Im ml 2 iwi 84057 20 _ 50 80 1250 10001 690 VAC Line Voltage S6R Drive Model Number HP KW D C Output Volts D C Output Amps CT Turns Ratio 29676 10 1875 1400 750 200 100001 840 58 20 S6R 1500A _____1250 10500 1 3 Appendix F Armature Current Feedback Resolution Current feedback normally has between 12 and 13 bits of resolution This resolution may be degraded if a Power Module is misapplied The Programming Executive software will warn you if this can happen because of any parameter entry errors you make The following explains how current feedback scaling is done and what you can
70. e which was entered as a configuration parameter This can be caused by a low line condition or a missing phase The system will automatically adjust the phase angle to give the correct current amount and will continue to fire SCRs as long as zero crossings are detected If zero crossings are no longer detected a fault condition will result 3 29 3 30 203 1 203 Drive Warning Register Continued Bit 3 Hex Value 0008H Var Name WRN_SYNO Range N A Access Read Only UDC Error Code N A LED N A Description The Synchronization Loss Fault Avoided bit is set when the system continues to operate through a temporary loss of A C line voltage Refer to register 202 1 202 bit 3 for more information Bit 4 Hex Value 001 OH Sug Var Name WRN_ILMO Range N A Access Read Only UDC Error Code N A LED N A Description The Current Reference Limit bit is set if the current reference exceeds the value entered as the Max Current Limit configuration parameter Bit 5 Hex Value 0020H Sug Var Name WRN_IDO Range N A Access Read Only UDC Error Code N A LED N A Description The Identification Test Error bit is set when an armature identification or field identification test fails This bit is also set when the resolver balance calibration test fails or yields unexpected results Bit 6 Hex Value 0040H Var Name WRN_FLDO Range N A Access Read Only UDC Error Code N A LED N A Descri
71. e either inputs or outputs If there are no bits assigned within a particular register pair then one 16 bit register can be an output and the other 16 bit register can be an input or both can be inputs or outputs Alternatively the entire register pair can be defined as a real or double integer value Note that if you are referencing a 32 bit value real or double integer in the UDC dual port from an AutoMax task the operation is being performed by the AutoMax Processor which operates on 16 bits of data at a time In such a situation you must employ some form of software handshaking in the AutoMax task to ensure that both the upper and lower order 16 bits represent the current value of the variable This is required for 32 bit values in the every scan register range It is possible to use software flags to indicate that data can be read It is also possible to read the data multiple times typically three times and compare the values 3 6 UDC Module Test I O Registers Registers 10004017 This view is used to configure the UDC module s Test Switch Inputs Register and the Meter Port Setup Registers 3 61 UDC Module Test Switch Inputs Register Register 1000 This view is used to configure the register that displays the status of the test switches and LED indicators on the UDC module Writing to this register will not change the state of the LEDs The status of this register is retained during a Stop All Bit 0 Hex Value 0001 H
72. e of the three parameters as allowed by the application If the gain is greater than 255 the programming terminal will display a warning that the maximum gain value has been exceeded The gain will be limited to 255 and the resolution of current feedback will be reduced For example if the CT ratio is 2000 1 full load current is 100 amps and maximum current limit is 150 then Gain 2000 255 10 2 100 1 50 0 75 222 Since the gain is within the acceptable range it is not limited When the gain is not limited the V F full scale of 2 MHz represents maximum current limit plus 7596 With a line frequency of 60 Hz this results in a maximum of 5555 counts per SCR firing With a line frequency of 50 Hz this results in 6666 counts per SCR firing As the full load current value decreases the gain must be increased to maintain the same resolution of current feedback If the example above were changed so full load current were 10 amps the calculated gain would be 2222 However because the gain is limited to 255 the V F can never reach 2 MHz In this example the 10 amps 225 results in 637 counts or approximately 9 bits of resolution When the gain is limited the maximum number of counts that will be read can be found with the following formula Maximum Counts 2 25 10 2 5555 This assumes current limit is 15096 and the A C line frequency is 60 Hz F 2 Appendix F Continued To determine how low ful
73. e value of the shunt field resistance Rf It is scaled in ohms times 10 This value can be generated automatically by commanding the field ID test in register 100 1 100 FLD TE Field Electrical Time Constant Default Current Value 0 Low Limit 0 High Limit 32767 Step 1 The value in this variable is the electric time constant of the field It is scaled in seconds times 1000 so that a time constant of of 0 1 seconds has a value of 100 The largest value that can be stored in this variable is 32 767 seconds This value can be generated automatically by commanding the field ID test in register 100 1 100 Appendix B Continued Resolver Gain and Balance Variables The resolver gain and balance variable values are used to compensate for varying lengths of resolver wiring The balance value can be generated automatically by commanding the resolver calibration test in register 101 101 The gain value will be generated automatically when the RES GAN variable is equal to Zero i e on power up Refer to the Power Module Interface Rack manual for more information on the calibration procedures Note that the Distributed Power Systems are designed to be used with the Reliance resolvers described in the PMI Rack manual The validity of the results of these calibration procedures are not guaranteed if resolvers other than those described are used RES GAN Resolver Gain Default Current Value 0 Low Limit 0 High Limit 255 Step
74. ecific parameter data Drive A 0 Drive B about the selected device View Field Data Q Speed Feedback Data Meter Port Selection 2 2 1 Armature Power Module Data Screen The Armature Power Module Data Screen allows you to enter specific information about the Power Module and motor to be used in your application See figure 2 2 Slot 1 UDC Parameter Entry SD3000 6 Pulse Current Armature Power Module Used 4 Ube Power System Configuration O Drive A 0 rive B AC tine Voltage Volts RMS e View Bridge Type MCR Connected To 8 Regenerative 8 DC Contactor 6 Armature Data Non Regenerative O AC Contactor O Field PM Data Speed Feedback Data Armature Power Module Ratings Meter Port Selection CT Turns DC Volts DC Amps Ratio X 1 Motor Armature Ratings Max Current volts Limit Figure 2 2 Armature Power Module Parameter Entry Screen e Armature Power Module Used The default setting is that an Armature Power Module is used If you are not using an Armature Power Module de select this option Power Svstem Confiauration Selections e A C Line Voltage Volts RMS Nominal preset voltage values are 230V default 380V 460V 575V or 690V You can also enter a custom value maximum 1 OOOV A C Note that the actual A C line voltage may be up to 1096 above the nominal voltage rating The A C line voltage determines which group of Power Modules may be s
75. elected from the wiring diagrams W D list This voltage will determine the threshold 1596 below this voltage at which the low A C line voltage warning will be indicated This voltage is also used in scaling the field A C line voltage and to avoid inverting faults Note that if the A C line voltage is greater than 750V A C the application requires an external voltage divider and a special phasing transformer in the Power Module e Bridge Type Select the type of bridge you are using either regenerative default or non regenerative MCR Connected To This parameter describes the type of MCR output on the Resolver amp Drive l O module The default setting is D C contactor You must select either an A C or D C contactor but not both If you do have both in your application the MCR output must be connected to the A C contactor and the D C contactor must be controlled by your application program Armature Power Module Rating Selections You can enter Power Module ratings either manually or automatically through the W D list e W D List You can choose from a list of wiring diagrams W D list and have the specified default Power Module values entered in automatically Appendix E lists these values D C Volts Enter the maximum output voltage the Power Module will produce The maximum allowable voltage is A C line voltage plus 35 The rated Power Module voltage cannot exceed 135 of the A C input voltage D C Amps Enter the
76. er Hex Value N A Var Name FML_ALPHA Range 5 to 180 Access Read Write UDC Error Code N A LED N A Description The value in the Field Test Angle register is the firing angle for the field alpha test Firing angles can range from 180 full off to 5 full on Any value outside of this range is internally clamped to be within the limits Note that the default value is 0 and the motors field must be disconnected for the lest to execute This register is only to be used with a single phase field The forward or reverse bridge is selected through bits 6 and 7 of the Drive Control register 100 1 100 THE PROGRAMMER MUST WRITE THE FIRING ANGLE VALUE INTO THE FIELD TEST ANGLE REGISTER 1044 104 BEFORE ENABLING THE FIELD ALPHA TEST THE ACTUAL MOTOR FIELD MUST NOT BE IN THE CIRCUIT UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED FAILURETO OBSERVETHIS PRECAUTION COULD RESULT IN BODILY INJURY 1051 105 Field Current Reference Register Hex Value N A Var Name FML_REF Range 4095 to 4095 Access Read Write UDC Error Code N A LED N A Description The value in the Field Current Reference register contains the reference current for the field current loop It is scaled so that 10096 of the hot amps value has a value of 4095 Any value writ ten here will be internally limited so as not to exceed 4095 A positive value in this register will turn on the forward bridge If a regenera
77. es not match the length encoded in the message itself Bit 5 Hex Value 0020H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Transmitter Underrun bit is set when the USC reports a transmit first in first out underrun 3 7 80 1 080 Bit 6 Hex Value 0040H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The CCLK Communication Synchronization Error bit is set when two or more CCLK counter ticks occur and no message is received Bit 7 Hex Value 0080H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The External Loopback Data Error bit is set during the UDC module loopback test if the transmit message does not match the receive message This test is performed only at power up or after a reset Bit 8 Hex Value 01 OOH Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Missed Gains bit is set if gain data from the PMI could not be written because memory was being written to when the gain values were received Bit 9 Hex Value 0200H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Multiplexed Data Verification Failure bit is set if data which is multiplexed into com mand feedback messages does not verify correctly Bit 10 Hex Value 0400H Sug Var Name N
78. file and configuration loaded In addition CCLK must be turned on in the AutoMax rack If the UDC tasks are already loaded onto the UDC module when the PMI requests its operating system the UDC module will also send information about when the PMI should send feedback register data required by the UDC task s This ensures that the data is measured or calculated as close as possible to the time it is needed in order to ensure it is as current as possible for the next scan of the UDC task s The UDC operating system determines the feedback register message timing required by examining the SCAN LOOP block in each UDC task so that the feedback will arrive at the UDC module just before it is needed For example if the TICKS parameter value in the SCAN LOOP block were 10 feedback data would be needed by the UDC module immediately before 10 x 500 usec time expires At first when the UDC module and PMI s are powered up and connected via the fiber optic link their system clocks are not synchronized In order for the PMI and UDC module to be synchronized to the same clock signal for communicating command and feedback data on a regular and predictable basis an AutoMax task must turn on the CCLK signal in the rack Until CCLK is turned on command and feedback messages are sent periodically but not on a predictable basis CCLK can be turned on by setting the appropriate bit in UDC register 2000 the interrupt status and control register for both A and B
79. g equation Maximum Amps Produced Amps x Maximum Current Limit by the Power Module 100 Must be less than the Power Module s output rating or 8000 amps maximum 2 2 2 Field Power Module Data Screen The Field Power Module Data Screen allows you to enter specific information about the 1 Phase Field Power Module and motor to be used in your application See figure 2 3 Slot 1 UDC Parameter Entry SD3000 6 Pulse Current Field Power Module Used UDC Drive Drive A Drive B Bridge Configuration AC Line Voltage Volts RMS T View Armature PM Data 2 Quadrant Q 4 Quadrant D reia rm vata Field Power Module Rating O Speed Feedback Data Meter Port Selection Motor Field Ratings Hot Amps Minimum Amps Field Safety Settings Field Loss Tum Off Trip Amps Delay Sec Figure 2 3 l Phase Field Power Module Parameter Entry Screen e Field Power Module Used The default setting is that I Phase Field Power Module is used If you are not using a I Phase Field Power Module de select this option Bri confi Line Voltage Volts RMS Preset voltage values are 230V default 380V or 460V You can also enter a custom value maximum 500V A C If an isolation transformer is used in the input power line to the Field Power Module enter the voltage from the secondary of the transformer e 2 Quadrant or 4 Quadrant A 2 quadrant non regenerative br
80. ge Output Rail J 3695 Each Rail I O port has a set of bits that display any errors that may occur and a fault counter that is incremented each time a bad communication check bit is detected The user s application program must regularly examine these bits and registers Refer to Tables 3 4 3 5 and 3 6 The check bit fault counter is reset to zero when a warning reset signal register 100 1 100 is generated through the UDC module from the application program Table 3 3 Rail I O Port Registers Rail Type and Signa eer 1 ouu mpu 2 fo Registers Port and Channel 4 Output 2 Output 1 04 Port 0 Channel 0 output 0 Input 0 FT eium CI presi I 18 Ponos output para NA 6 Pau Regier ates 5 17 __ Check Bit T Counter Register Tables 3 4 3 6 a ron impuro OMR DA A ri caer 1 out mat 1 A A re o wear iz Crane 3 3 Jnpur 10 22 Port 1 Fault Register Tables 3 4 3 6 Port 1 Check Bit Fault Counter Register Tables 3 4 3 6 1 4 Output Analog Rail Module MN 61 C365 61 C366 2 4 Input Analog Rail Module M N 61 C345 61 C346 3 2 Output 2 Input Analog Rail Module MIN 61 C350 61 C351 4 Digital 1 O Rail M N 45C1 Thumbwheel Switch Input Module M N 45C630 or LED Output Module M N 45C631 Table 3 4 Fault Register and Check Bit Fault Counter Register
81. gnals to the armature and l phase field Power Module SCR gates for variable speed control of D C motors For armature current regulation the PMI Processor compares the desired current reference to the measured armature current and voltage integrated from SCR firing to SCR firing The armature current reference is calculated in a UDC task and sent to the PMI Processor at the end of each UDC scan Voltage to frequency converters are used to compute average current and voltage in order to avoid errors inherent in sampling e g measuring during noise spikes or A C line dips Armature feedback and CEMF are used to determine the proper gate firing time for SCR pairs every 1 6th of the line every 2 78 msec on average at 60Hz The armature current regulation algorithm provides for linear regulation over a full range of operating conditions such as A C line fluctuations continuous and discontinuous conduction and speed changes For field current regulation the PMI Processor compares the desired output current reference calculated in a UDC task to the measured field feedback The PMI Processor uses current error and CEMF to determine the proper gate firing time for the 1 phase field Power Module SCR thyristor pairs every 1 2 cycle of the line every 8 33 msec on average at 60 Hz Field current regulation is programmable which provides for field weakening field trim field economy and field loss protection The PMI Processor scans its Resolver amp D
82. hange If the actual data being sent to the meter port is significantly smaller than the upper and lower limits assigned by the programmer the effective resolution of the 8 bit D A circuit 1 part in 255 will degrade To calculate the step change indicated on the meter port calculate the sum of the absolute values of the upper and lower limits the entire range of possible values assigned to the port Then scale this number by 255 in order to determine the minimum step change that will cause the D A output to change For example suppose the programmer sets the 1 0V and 1 OV limits at 4095 and 4095 respectively but the actual value varies only between 1 024 and 1024 Then 8190 255 32 counts 3 42 This means that although the actual data is being updated the meter port output will change only when the data changes by 32 or more counts This level of granularity might be acceptable if the range of the data were actually 8190 counts but might not be acceptable if the data range is only 4095 counts If the programmer had assigned the limits 1024 the D A output step change would be only 8 counts 2048 255 8 1001 Initiate Change in Setup Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Set this register equal to a non zero value to store the new setup register configurations in UDC memory You must use this register whether you are changing the meter po
83. he field are identified Note that if you have performed auto tuning and the results of the Identification test are consistently at the tunables upper lower limits the local tunable values may be clamped in which case you may have to change the CURRENT value Refer to section 4 2 2 for more information THE PROGRAMMER MUST WRITE THE FIRING ANGLE VALUE INTO THE FIELD TEST ANGLE REGISTER 104 1104 BEFORE ENABLING THE FIELD ALPHA TEST THE ACTUAL MOTOR FIELD MUST NOT BE IN THE CIRCUIT UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED FAILURE TO OBSERVETHIS PRECAUTION COULD RESULT IN BODILY INJURY value is entered into the Field Test Angle register 104 1 104 FLD_ALPHA This test is for the single phase field only To test the reverse bridge also set bit 7 315 3 16 1001100 Drive Control Register Continued Bit 7 Hex Value 0080H Var Name FML_ATRO Range N A Access Read Write UDC Error Code N A LED N A Description The Field Alpha Test Polarity bit is set to select the reverse bridge for the field alpha test Bit 6 must also be set The firing angle value is entered into the Field Test Angle register 104 1 104 FLD_ALPHA This test is for the single phase field only If this bit is not set the forward bridge will be tested Bit 8 Hex Value 01 00H Var Name FLT_RSTO Range N A Access Read Write UDC Error Code N A LED N A Description The Fault Reset bit
84. he rated IR drop the field will automatically be weakened in order to maintain constant CEME This maintains CEMF at its maximum value which is found at motor base speed The field control algorithm uses the smaller of the following values either the value entered into the Field Current Reference register 105 1 105 or the algorithm calculated value designed to keep CEMF constant The Disable Field Weakening bit is set to disable automatic field weakening When automatic field weakening is disabled the programmer has exclusive control over the field current reference value This does not mean that field weakening cannot be done only that field weakening will not be done automatically by the field control algorithm The programmer must provide the proper field control reference value Refer to Appendix H for more information The figure shows the field current regulation algorithm with field weakening disabled Note that if the programmer selects No Speed Feedback during parameter entry automatic field weakening will be disabled and the status of the Disable Field Weakening bit will be ignored by the PMI OS 1004 100 Drive Control Register Continued Bit 15 Hex Value 8000H Sug Var _RUNO Range N A Access Read Only UDC Error Code N A LED N A Description The UDC Task Running bit is a status bit that indicates that the UDC task is running This bit is used by the PMI Processor to prevent the minor loop from
85. he task that executes after the initial scan of the task after a STOP ALL command and subsequent Run command or after power is cycled to the rack 6 Motor thermal overload protection Electronic thermal overload protection for Distributed Power drives is normally provided by the THERMAL OVERLOAD block The following briefly describes how the THERMAL OVERLOAD block works how to program the block and what adjustments are possible Each UDC task must contain a THERMAL OVERLOAD block unless motor thermal overload protection is provided by a hardware device See J 3676 the Control Block Language instruction manual for the structure of the block CAUTION Electronic motor overload protection must be provided for each motor in a Distributed Power drive application to protect the motor against excessive heat caused by high currents This protection can be provided by either the THERMAL OVERLOAD software block or an external hardware device Applications in which a single power module is controlling multiple motors cannot use the THERMAL OVERLOAD software block and must use an external hardware device or devices to provide this protection Failure to observe this precaution could result in damage to or destruction of the equipment The THERMAL OVERLOAD control block is used to create a model of the temperature in a single device such as a motor or power module controlled by a DPS drive and to turn on an alarm when an overload condition exi
86. ic communication between the PMI Processor and the UDC module is lost due to two consecutive communication errors of any type This bit is set only after communication between the PMI Processor and the UDC module has been established Refer to section 4 2 3 for additional information Also refer to the CCLK Synchronized bit register 200 1 200 bit 14 2031 203 Drive Warning Register The warnings indicated by this register cause no action by themselves Any resulting action is determined by the application task The user must ensure that the AutoMax application task monitors register 203 1 203 and takes appropriate action if any of these conditions occur When a warning condition is detected these bits are latched until the Warning Reset bit bit 9 of the Drive Control register register 100 1 100 is set to 1 and then cleared Bit 0 Hex Value 0001 H Var Name WRN_SCRO Range N A Access Read Only UDC Error Code N A LED N A Description All SCRs are not carrying the same the load A bit is set in the SCR Diagnostic register register 204 1204 to indicate which SCR is not working properly Refer to the SCR tunable section 6 2 2 3 for more information Bit 1 Hex Value 0002H Sug Var LAC Range N A Access Read Only UDC Error Code N A LED N A Description The Low Line Voltage Phase Missing bit is set when the system detects that the line voltage is less than 85 of its nominal valu
87. idge is the default selection Select the 4 quadrant bridge for regenerative operation Field Power Module Selections You can enter Power Module ratings either manually or automatically through the W D list e W D List You can choose from a list of wiring diagrams W D list and have the specified default I Phase Field Power Module values entered in automatically Appendix E lists these values D C Amps Enter the Field Power Module s D C Amps output value which can range from 1 to 100 Amps There is no default value This value is found on the Power Module s nameplate and is used to scale field current feedback Motor Field Ratina Selections Hot Amps There is no default value This is the current that will be generated by the field power supply when current reference is at maximum This value is found on the motor s nameplate and can range from 0 01 to 99 99 Amps e Minimum Amps There is no default value This is the minimum output current that the field power supply will produce when it is enabled This value is found on the motor s nameplate and can range from 0 01 to 99 99 Amps Field Safety Setting Selections e Field Loss Trip Amps There is no default value This parameter is the point at which a field loss will be detected and can range from 0 01 to 99 99 Amps Refer to register 202 1 202 for more information e Turn Off Delay Sec This is the amount of time the field will remain energized after a fault condition The
88. is 114 and TRIP TIME is 60 seconds When I FDBK is at 100 CALC RISE will reach a steady state value of 1000 100 2 IO With THRESHOLD at 114 the trip point for CALC RISE will be 1300 11 2 10 If I FDBK is at steady state 100 and then is stepped to 1 50 CALC RISE will integrate up to 1300 in 60 seconds and OVERLOAD will turn on The OVERLOAD output will stay on until the rise decays to less than 1000 If I FDBK remains less than 114 CALC RISE will remain less than 1300 and OVERLOAD will not turn on The rate at which the CALC RISE block parameter counts up and down is calculated so that a step from 100 to LIM BAR will turn on the OVERLOAD in TRIP TIME seconds If current feedback steps from 10096 to a value less than current limit it will take longer to detect the overload If FDBK is stepped from zero to LIM BAR the block will take approximately four times the value of TRIP TIME to detect the overload UL 508C section 56 1 3 specifies that when subjected to 20096 of rated full load motor current the overload protection must trip in at least eight 8 minutes Because TRIP TIME is calibrated from 100 to current limit and TRIP TIME from zero to current limit is approximately four times longer the maximum trip time that is allowed is 2 minutes 120 seconds To meet UL listing requirements any value greater than 120 seconds is internally limited to 120 seconds The National Electric Code 430 32 1993 requires that
89. it 11 Hex Value 0800H Sug Var Name WFI_FLT Range N A Access Read Only UDC Error Code N A LED N A Description The Field Faults Need to be Reset bit is set if previous field faults register 202 1202 i e field loss and line synchronization loss faults have not been cleared 3 35 3 36 206 1 206 A C Line Voltage Feedback Register Hex Value N A Sug Var Name AC VRMS RMS Volts Range N A Access Read Only UDC Error Code N A LED N A Description The A C Line Voltage Feedback register displays the measured A C RMS line voltage A value of is equal to 1 volt 2071207 Current Minor Loop Feedback Register Hex Value N A Var Name CML_FB Range N A Access Read Only UDC Error Code N A LED N A Description The Current Minor Loop Feedback register displays the measured armature current DC Amps feedback in counts A value of 4095 is equal to the maximum current limit setting entered during parameter entry This register is used as the I FDBK parameter in the THERMAL OVERLOAD control block used in DPS drives to monitor the motor for thermal overload 2081 208 Armature Current Feedback Register Hex Value N A Var Name ARM IFB Amps x 10 Range N A Access Read Only UDC Error Code N A LED N A Description The Armature Current Feedback register displays the measured armature current D C Amps The current is measured to within a tenth of an amp The displa
90. ither Xl X2 or X5 2 2 1 Meter Port Selection Screen The Meter Port Selection parameter screen allows you to enter specific information about what variables are to be output on the four PMI D A channels the four meter ports on the PMI Processor module See figure 2 7 Slot 1 UDC Parameter Entry SD3000 6 Pulse Current Meter Port 1 Armature Current Feedback Counts UDC Drive Diea Vaue tov vauee 10v 204 75 Units Volt 2047 5 Units at 0 V View Armature PM Data Meter Port 2 PotNotUsed T Field PM Data Speed Feedback Data Meter Port Selection oe tov Value 10V 100 5 00 Units Volt 50 0 Units at 0 V Value 10V i 8 Value 10V 200 00 Units Volt 2000 0 Units at 0 V Figure 2 7 Meter Port Selection Entry Screen 2 10 Figure 2 8 shows the values that can be displayed on the meter ports These values described in detail in chapter 3 You must enter a Minimum Value and a Maximum Value for each selection except for those marked as Port Not Used The Minimum Value is the value at which to output 1 0V The Maximum Value is the value at which to output 1 OV The system software then places the units per volt on the screen based on the Minimum Maximum Values The Minimum Value must not be less than 32768 The Maximum Value must not be greater than 32767 The Minimum Value must be less than the Maximum Val
91. ive may be re started after turning the com mand bits off and then back on again If the fault conditions still exist the identifying bit in this regis ter will immediately be set again The fault conditions reported in this register result in turning off the drive The UDC task is not stopped automatically when a drive fault occurs unless it is specifically instructed to in an application task The user must ensure that the AutoMax application task tests register 202 1202 and takes ap propriate action if a fault occurs Note that the status of this register is also reported in the error log for the task in which the error oc curred Bit 0 Hex Value 0001 H Var Name FLT_SCRO Range N A Access Read Only UDC Error Code 1000 LED PM FLT on the PMI Processor module Description The Shorted SCR Fault bit will be set if a shorted SCR is detected Check register 204 1204 to identify the SCR that has shorted Bit 3 Hex Value 0008H Var Name FLT_SYNO Range N A Access Read Only UDC Error Code 1003 LED EXT FLT on the PMI Processor module Description The A C Line Synchronization Fault bit is set when the A C line voltage is missing for more than 2 seconds See register 203 1203 bit 3 for more information Bit 4 Hex Value 001 OH Sug Var Name FLT_IOCO Range N A Access Read Only UDC Error Code 1004 LED EXT FLT on the PMI Processor module Description The Instantaneous Overcurrent Fault bi
92. l load current can go before the gain will be limited and resolution degraded use the following equation full low limit CT 10 2 I limit 75 Using the same CT ratio of 2000 1 the low limit of full load current is 87 amps If your full load current is less than the result of this calculation and you do not want to sacrifice current feedback resolution you must use a CT with fewer turns on the secondary or add more turns to the primary to lower the overall CT ratio To determine how high full load current can go before the gain will be limited use the following equation full high limit CT 255 10 2 26 I limit 75 Using the same CT ratio of 2000 1 the high limit of full load current is 855A If your full load current is greater than the result of this calculation you must use a CT with more turns on the secondary or remove turns from the primary to raise the overall CT ratio Appendix G Drive Control Register Operating States The following table indicates which Drive Control register 100 1 100 commands can be executed at the same time Armature Current CML Control Modes Alpha Alpha Idle Test Test default Forward Reverse Test Run Idle default Alpha Test Forward Field Current FML Control Modes Alpha Test Reverse Test Run field control required on drives with single phase field Power Modules G7 Appendix H Field Current Regulation Algorithm with
93. le to respond to an interrupt from the UDC module Registers within this range that are written to by an AutoMax task are read by the UDC operating system from dual port memory and copied into the UDC local memory at the beginning of the Nth scan See figure 3 2 aut ui depane ASE OU IM eses si sydnuejur pue sejyejn JAN ueewjeq emau eui ASE se Bug SY y x4 Sg J088820Jd XEWOJNY i se xeyyomy eui Aq 4581 eui uo si 199 pue v sse ujoq o1 pue y syst yey 5 ULOS YIN Yale 109 jeu J0SS820Jg 8181619 QN eM sejeJeueD wejs s Buneiedo Jan v xsel 0 indui yey sysiBas ueos Asana yoye Han woy sydney V A58 0 s ndu se ASeL 105592014 XENONY pesn sJejsiBeJ ueos Yale V WON 5 ee yey V X88 sindino yey SJejsiDe1 ueos ana OM 5 ueos je e SUA 4383 0 sindur yey sJejsiDe1 weos ue e YLT woy peo ese yey SJe iie usos JejsiBeJ ULOS OWIM e OWM n Ol LIT A SBA Ni andu inco v un vinduy guru nao y uny Ty ndu I
94. ly executes the first time that the task is scanned after a STOP ALL command and subsequent Run command or after power is cycled to the rack 4 SCAN LOOP block Enabling CCLK This control block tells the UDC operating system how often to execute the task based on the constant clock CCLK signal on the rack backplane Note that the CCLK signal must be enabled by a task in the rack before any UDC tasks in the rack can be scanned beyond their SCAN LOOP blocks Note that CCLK must be enabled again after a STOP ALL in the rack CCLK is enabled by setting the appropriate CCLK enable bit on certain modules in the rack such as the UDC module CCLK must be enabled on one module only If CCLK is enabled on multiple modules in the rack an overlap error will result error code 38 The UDC task runs based on ticks one tick is equal to one 500 usec 5 msec CCLK interval The value can range from 1 to 20 ticks The programmer must specify how often the task should run in the TICKS parameter of the SCAN LOOP block in the task itself The TICKS value represents the number of 500 usec intervals within which the task must execute or an overlap error will occur In order to calculate this value both drive A and drive B tasks must be considered together because they execute one immediately following the other A then B See figure 4 1 for more information When determining the value to enter the programmer must consider how long it will take both t
95. m the Configure menu A dialog box listing the available modules will be displayed on the screen Step 3 Select the UDC module Step 4 Select a product type and a regulator control type for both drive A and drive B See section 2 1 1 for regulator selection rules The remainder of this chapter assumes you have selected an SD3000 drive type Step 5 Select OK to add the UDC module to the rack and return to the Rack Configurator screen 2 1 2 2 11 1 2 2 Rules for Configuring Selecting Drives for the UDC Module 1 Both A and B drives do not have to be used You can configure only one 2 Your A B drive type combination is restricted only if you select either an SD3000 12 Pulse drive or an SF3000 drive for either drive A or drive B For these products you are restricted to the drive type combinations shown in the table below All other drive type combinations are allowed If you choose for Drive A Then your choices for Drive B are SD3000 12 Pulse SD3000 12 Pulse Auxiliary No PMI Attached SF3000 SD3000 6 Pulse SF3000 Entering the Drive Parameters Drive parameters are application specific data that describe your installation s Power Modules feedback devices and motors This information is loaded to the UDC module which in turn automatically downloads it to the PMI when the two are first connected over the fiber optic link This information is also stored off line with the Programming Executive Note
96. mature and field ID commands respectively in register 100 1 100 Crossover frequency for both the armature and the field must be entered by the user if the default CURRENT parameter is not acceptable The STEP parameter for all the variables is always one 1 CML WCO Current Minor Loop Crossover Frequency Default Current Value 200 Low Limit 0 High Limit 400 Step 1 The value in this variable selects the desired response of the current minor loop The units are in radians per second The higher the value the more quickly the drive responds to a change in reference current Also note that the higher the value the less stable the system response becomes ARM CCT96 Armature Threshold Current Default Current Value 0 Low Limit 0 High Limit 32767 Step 1 The value in this variable is the armature current at the threshold of continuous conduction The units are in amps times 10 For example a threshold current of 1 Amp would be entered as a value of 10 This value can be generated automatically by commanding the armature ID test in register 100 1 100 ARM R Armature Resistance Default Current Value 0 Low Limit 0 High Limit 32767 Step 1 The value in this variable is the resistance of the armature when it is in continuous conduction The value is displayed ohms x 100 For example an armature resistance of ohm would be entered as a value of 1000 This value can be generated automatically by commanding the arma
97. munication Warning bit is set when a fiber optic communication error is detected between the PMI Processor module and the UDC module Communication errors in two consecutive messages will cause a drive fault 204 1 204 SCR Diagnostic Register The Shorted SCR Test is executed by the PMI Processor when RUNGQ is first turned on If the SCR is not firing correctly bit O of register 203 1203 will be set The bits set in the SCR Diagnostic register indicate which SCR is shorted or not firing This register is reset when either the Fault Reset bit bit 8 or the Warning Reset bit bit 9 of the Drive Control register register 100 1 100 is turned on For a regenerative drive this register indicates the pair of SCRs that have a fault For a non regenerative drive this register indicates the specific SCR that failed Bit 0 Hex Value 0001 H Sug Var Name SCR 01 Range N A Access Read Only UDC Error Code N A LED N A Description SCR 1 Fault Forward Bridge Bit 1 Hex Value 0002H Sug Var Name SCR 02 Range N A Access Read Only UDC Error Code N A LED N A Description SCR 2 Fault Forward Bridge Bit 2 Hex Value 0004H Sug Var Name SCR 039 Range N A Access Read Only UDC Error Code N A LED N A Description SCR 3 Fault Forward Bridge 3 31 3 32 204 1 204 SGR Diagnostic Register Continued Bit 3 Hex Value 0008H Sug Var Name SCR 049 Range N A Access Read Only UDG Error Code
98. n fauft FLT RUNG 15 PMI communication lost FLT COMQ 203 1203 Drive warning Bit 0 SCR s not firing WRN_SCRO 1 Low line or phase missing WRN _LAC 3 Sync loss fault avoided WRN_SYN 4 Current limit exceeded WRN_ILM 5 Identiftcatlon test error WRN ID 6Field pw module overcurrent WRN_FLD 12PMI fan loss WRN_FAN 13 Rail communication error RALO 14 CCLK not synchronized WRN_CLK 15 PMI communication error WAN COMO 20411204 SCR diagnostic Bit 0 SCR 1 fault SCR01 1 SCR 2 fault SCR_02 2 SCR 3 fault SCR_03 3 SCR 4 fault SCR_04 4SCR 5 fault SCR_05 5 SCR 6 fault SCR_06 6SCR11 fault SCR 119 7 SCR 12 fault SCR 129 6 SCR 13 fault SCR 13 9 SCR 14fault SCR 149 10SCR 15fault SCR 15 11 SCR 16fault SCR 1 60 A I A 2 FEEDBACK AB 205 1205 Interlock Bit 0 Multiple CML requests ILLO 1 Arm parameters not loaded WCI_CNF 2 Arm gains not loaded GANG 3 Arm faults need to be reset WCI_FLT REGISTERS Continued 4 Run permissive missing WCI_RPI 5 Arm field not ready WCI_FNRO 6 Arm field not allowed 7 M contactor did not close WCIMCRO 8 Multiple field requests WFI ILLO 9 Field parameters not loaded WFI_CNF 10 Field gains not loaded WFI_GANO 11 Field faults need to WFI_FLT be reset 206 1206 AC line voltage feedback AC_VRMS 2071 207 CML feedback CML_FB 2081 208 Arm current fdbk ARM_IFB 10 1 amp 209 1209 Arm voltage fdbk ARM VFB 1 1 volt 210 1210 Counter EMF
99. nge N A Access Read Only UDC Error Code N A LED N A Description The Resolver Balance Calibrated bit is set when the resolver balance calibration proce dure is complete This procedure is performed when the Enable Resolver Calibration bit register 101 1 101 bit 6 is set and the motor is turning Bit 8 Hex Value 01 Sug Var Name STR DET Range N A Access Read Only UDC Error Code N A LED N A Description The External Strobe Detected bit is set when the external strobe on the motor s resolver is detected Register 216 1 216 displays the position of the resolver at the time of the strobe Note that this bit is set for only one scan allowing a strobe to be detected every scan The UDC task must check the External Strobe Detected bit each scan to ensure the validity of the strobe data in register 216 1 216 Bit 9 Hex Value 0200H Sug Var Name STR LVL G Range N A Access Read Only UDC Error Code N A LED N A Description The External Strobe Level bit is set or reset by the system when the external strobe is detected It indicates whether the external strobe level was rising 1 or falling 0 3 25 3 26 202 1 202 Drive Fault Register The bits in the Drive Fault register indicate the cause of a drive shutdown The bits in this register are latched until they are reset by setting the Fault Reset bit bit 8 of the Drive Control register 100 1 100 After turning the Fault Reset bit on the dr
100. nt Feedback Resolution Appendix G Drive Control Register Operating States Appendix H Field Current Regulation Algorithm with Field Weakening Turned Off Appendix Instantaneous Overcurrent Trip Point Appendix D C Amp Rating Parameter Precautions B C I C 2 C 3 D I E G4 H4 J l List of Figures Figure 2 1 503000 Drive Parameter Entry Screen 2 3 Figure 2 2 Armature Power Module Parameter Entry Screen 2 4 Figure 2 3 Field Power Module Parameter Entry Screen 2 6 Figure 2 4 Speed Feedback Parameter Entry Screen With No Feedback Device Selected 2 8 Figure 2 5 Speed Feedback Parameter Entry Screen With A Resolver Selected 2 8 Figure 2 6 Speed Feedback Parameter Entry Screen With An Analog Tachometer Selected 2 9 Figure 27 Meter Poit Selection Entry Screen sank HR 240 Figure 2 8 PMI Meter Port Parameters 503000 2 1 1 Figure 3 1 Typical UDC Task Scan u a CR tae 3 38 ride 3 2 NIB Sean ee eek 3 39 Figure 4 1 Typical UDC Task Scan 5 es Rhe FREE Aa 4 2 Figure 4 2 Data Time Flow for UDC Module and PMI 4 8 Figure 4 3 Nth Scan Interrupts v sois du cce me td erat debere board s 4 10 List of Tables Table 3 1 UDC Module
101. o be mapped to port 3 Enter a value of 100 bit 00 to 115 bit 15 as required Enter a value of zero if all of the register s bits are to be displayed 1012 UDC Module Meter Port 3 Maximum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Set this register to the number that will represent 10V The maximum allowable value is 32767 1013 UDC Module Meter Port 3 Minimum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Set this register to the number that will represent 10V The minimum allowable value is 32768 Meter Port 4 1014 UDG Module Meter Port 4 Register Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDG Error Code N A LED N A Description UDC register number 0 2044 to be mapped to meter port 4 1015 UDG Module Meter Port 4 Bit Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDG Error Code N A LED N A Description Bit number of the UDC register specified in register 1014 that is to be mapped to port 4 Enter a value of 100 bit 00 to 115 bit 15 as required Enter a value of zero if all of the register s bits are to be displayed 1016 UDG Module Meter Port 4 Maximum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDG E
102. o request the M contactor if present to close and to start the drive i e this bit tells the PMI Processor to begin executing the current minor loop When this bit is turned off zero current is commanded until discontinous conduction is detected and then the M contactor if present is opened See register 200 1 200 bit 1 Refer to register 205 1 205 for additional information on the Interlock register Bit 1 Hex Value 0002H Sug Var Name ID 2 Range N A Access Read Write UDC Error Code N A LED N A Description The Enable Armature Identification Test bit is set to start the test in which the resistance and time constant of the armature are identified This bit must stay on during the test Refer to regis ter 200 1 200 bit for more information Note that if you have performed auto tuning and the results of the Identification test are consistently at the tunables upper lower limits the local tunable values may be clamped in which case you may have to change the CURRENT value Refer to section 4 2 2 for more information Bit 2 Hex Value 0004H Var Name CML_ATO Range N A Access Read Write UDC Error Code N A LED N S Description The Enable Armature Alpha Test bit is set to start the alpha test of the armature This bit only enables the test The firing angle value is entered into the Armature Test Angle register 102 1 102 CML ALPHA The status of bit 3 defines which bridge is tested either
103. of the drive The bits reflect the status of the activity initiated through the Drive Control register register 100 1 100 Bit 0 Hex Value 0001 H Sug Var Name CML ONG Range N A Access Read Only UDC Error Code N A LED N A Description The PMI Processor sets the CML On bit in response to the CML_RUN command after all of the interlock tests are passed to indicate that the minor loop is running and the motor is energized Bit 1 Hex Value 0002H Var Name CML_IDCO Range N A Access Read Only UDC Error Code N A LED N A Description The Armature Identification Test Complete bit is set when the armature identification test is finished See register 100 1 100 bit 1 When the request for the function is turned off this bit will be turned off Bit 2 Hex Value 0004H Var Name CML_LIM Range N A Access Read Only UDC Error Code N A LED N A Description The Current Minor Loop in Limit bit is set when the advance of the firing angle is being limited or the bridge is full on This bit is normally off Bit 3 Hex Value 0008H Sug Var Name CML_MAX Range N A Access Read Only UDC Error Code N A LED N A Description The Maximum Firing Angle Reached bit is set by the PMI Processor when the system is firing at the maximum firing angle of 150 3 21 200 1 200 Drive Status Register Continued Bit 4 Hex Value 001 OH Var Name FML_ONO Range N A Ac
104. on Any value outside of this range is internally clamped to be within the limits The forward or reverse bridge is selected through bits 2 and 3 of the Drive Control registers 100 1 100 Note that the default value is 0 and the motor must be disconnected for the lest to execute THE PROGRAMMER MUST WRITE THE FIRING ANGLE VALUE INTO THE ARMATURE TEST ANGLE REGISTER 102 1102 BEFORE ENABLING THE ARMATURE ALPHA TEST THE ACTUAL MOTOR ARMATURE MUST NOT BE IN THE CIRCUIT UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY 103 1 103 Armature Current Reference Register Hex Value N A Sug Var Name CML_REF Range 4095 to 4095 Access Read Write UDC Error Code N A LED N A Description The value in the Armature Current Reference register contains the current reference for the armature current minor loop It is scaled so that the maximum current limit value that was entered as a configuration parameter has a value of 4095 Any value written here will be limited internally 10 not exceed 4095 A positive value in this register will turn on the forward bridge If regenerative Power Module is being used a negative value in this register will turn on the reverse bridge Refer to registers 207 1207 current feedback in counts or registers 208 1208 current feedback in amperes for more information 3 19 3 20 1044 104 Field Test Angie Regist
105. on The Interrupt Enabled bit when set to one by the operating system indicates that a hardware EVENT has been defined in AutoMax task No other programming is required for the UDC operating system to generate an interrupt in the interval defined in register 2001 Bit 15 Hex Value 8000H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Interrupt Status bit when set to one indicates that an interrupt is being generated at this time 2001 Scans Per Interrupt Register Hex Value N A Var Name SPI Range N A Access Read Write UDC Error Code N A LED N A Description The Scans Per Interrupt register contains the number of times a UDC task is to be scanned between updates of the Nth scan application registers Note that you must write the desired value to this register before you turn on CCLK The default value is zero Le not applicable because an interrupt is not being used but is updated each scan One is an allowable value If a hardware EVENT is defined in an AutoMax application task this register will also specify when the interrupt oc curs i e every Nth scan See chapter 4 and figure 4 3 for more information on interrupts Note that in this register one scan is a complete scan of both tasks A and B 3 49 4 0 APPLICATION PROGRAMMING FOR DPS DRIVE CONTROL DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION O
106. ore the beginning of every scan of the UDC task i e immediately before the CCLK timer expires Each message contains the data for registers 200 221 1200 1 221 as well as any rail data that has changed from the last feedback message The exchange of command and feedback register data is synchronized through the use of the constant clock signal the UDC module as described below CCLK also enables the coordination of all UDCs in a rack because they will all use the same time base for task execution Note that all UDC modules in a rack are not required to have the same value in the TICKS parameter of the SCAN LOOP block in both their tasks In other words if the UDC module in slot 6 has TICKS 10 in its tasks and the UDC module in slot 7 has TICKS 20 in its tasks the tasks on the UDC module in slot 6 will execute twice as often as the tasks on the UDC module in slot 7 but they will execute on the same time basis i e time zero is determined by CCLK timer expiration As soon as the UDC module and PMI are connected over the fiber optic link the PMI will request its operating system from the UDC module Recall that the PMI operating system is part of the UDC operating system As long as the UDC module has its own operating system and parameter object file it will download to the PMI the correct operating system In order for the PMI and the UDC module to be synchronized the UDC module must have its operating system parameter object
107. over the DCS NET network which is used for all connections to the rack 44 Any UDC dual port register that is to be used in a UDC task must be defined as COMMON in the task Recall that UDC dual port memory registers are either reserved for a specific use such as rail data or available for application specific purposes to the programmer Registers that are not specifically identified in one of these two ways in the Programming Executive software or in this instruction manual must not be written to by either the UDC or AutoMax tasks because they are being used by the operating system Generally the common variables on the UDC module are either written to only by AutoMax tasks read only to UDC tasks or they are written to only by a UDC task read only to AutoMax tasks The former are typically variables that control an action e g requesting the minor loop to run and the latter are typically status variables e g indicating the status of the fiber optic communication link UDC tasks can access only the UDC module s own dual port memory They cannot access other variables in the rack unless an AutoMax task writes those variable values to the application specific registers in the UDC dual port Figure 4 1 illustrates one UDC task scan J UDC Scan Latch every scan registers that are inputs to task B Write every scan registers that are outputs from task A S a 3 3 v z
108. ption The Field Power Module Overcurrent bit is set if the Field Power Module s field current feedback value is greater than 1 5 times the Hot Field Amps parameter value for 1 second This condition can cause errors during the field ID test or when the field is turned on These errors can be caused by miswiring the 181 and 183 A C line to the field Power Module Bit 12 Hex Value 1 OOOH Var WRN_FANO Range N A Access Read Only UDC Error Code N A LED N A Description The PMI Fan Loss Warning bit is set when airflow through the PMI rack is not being sensed The airflow is monitored by a solid state airflow switch in the PMI power supply Bit 13 Hex Value 2000H Sug Var Name WRN_RAL Range N A Access Read Only UDC Error Code N A LED RAIL FLT on the PMI Processor module Description The Rail Communication Warning bit is set when a rail communication problem is detected and logged in registers 4 10 16 or 22 Refer to Tables 3 4 to 3 6 203 1 203 Drive Warning Register Continued Bit 14 Hex Value 4000H Var Name WRN_CLKO Range N A Access Read Only UDC Error Code N A LED N A Description The CCLK Synchronized in PMI Warning bit is set when the CCLK counters in the PMI Processor and the UDC module are momentarily not synchronized Bit 15 Hex Value 8000H Sug Var Name COMO Range N A Access Read Only UDC Error Code N A LED N A Description The PMI Com
109. r 100 1 100 are set The first problem detected will be indicated by the corresponding bit in this register These bits will remain latched until a Warning Reset is issued by the setting and clearing of bit 9 of register 100 1 100 Note that these bits will prevent the CML or FML from running Refer to the DPS SD3000 Diagnostics Troubleshooting and Startup Guidelines Instruction Manual S 301 1 for more information about the interlock tests Bit 0 Hex Value 0001 H Sug Var Name WCI _ILL Range N A Access Read Only UDC Error Code N A LED N A Description The More Than One CML Request bit is set when more than one incompatible CML operating mode is requested at a time in register 100 1 100 The following operating modes are mutually exclusive e Armature Alpha Test e Armature Identification Test e CMLRun This bit is also set if the CML is turned on when the UDC task is not running This bit is also set if you have attempted to restart the drive without resetting the appropriate command bits from register 100 1 100 Recall that the bits in register 100 1 100 are edge sensitive See Appendix for additional information Bit 1 Hex Value 0002H Sug Var Name WCI CNF Range N A Access Read Only UDC Error Code N A LED N A Description The CML Parameters Are Not Loaded bit is set if the armature configuration parameters have not been downloaded into the UDC module from the Programming Executive 3 33 3 34
110. rive I O module D C Technology module and rail I O in concert with armature and field current regulation so that I O data can be integrated into both the PMI control algorithms and into UDC tasks as required The following figures show block diagram representations of both the armature and field current regulation algorithms 2 Appendix SD3000 Armature Current Regulation Algorithm SNHA 84 TWO SWHA OV 9682A WHY gJA 96100 WHY duo 84 WO useJu 31 WHY 96H WHY y ESTIMO X INT dOHd 338 1WO OV uoe 59120 HOS amod 30 yne3 09M TINO ION 9684 WO eouenbeg ONO IWO NNY IWO WI juang 4 Appendix SD3000 Field Current Regulation Algorithm SWHA OV 84 IWS 9e3cvg 4 9 35 9 JW3 9 602M WO INI dOHd SWHA OV LOH 014 9631 014 4 Cd WO Jusundg 4 _ 84 A 3W3 SAV ISV8 JING 438 AJ 8W3 TN C 5 Appendix D Status of Data in the AutoMax Rack after a STOP ALL Command or STOP ALL Fault AutoMax PMI LOCAL tunable variables LOCAL variables non volatile are COMMON memory variables retained others are N A N A reset to 0 inputs retained and ceca Un ED anal pele updated outputs are see below all O is reset to 0 reset to 0 Input
111. rresponding to the resolver s position Access Read Only UDC Error Code N A LED N A Description The Resolver Strobe Position register displays the electrical position of the resolver at the time a strobe signal is detected 3 37 3 38 3 9 Application Registers Registers 300 599 Every Scan Registers 13004599 Every Nth Scan The application registers are used to pass application specific data between an AutoMax Processor and the UDC module Memory is allocated for a maximum of 600 application registers which are used by both tasks A and B There are 300 registers that can be used every scan registers 300 599 and 300 registers that can be used every Nth scan registers 13004599 N is defined in register 2001 Note that the status of application registers is not retained after a Stop Application registers 300 599 can be used every scan of UDC tasks Registers within this range written to by a UDC task are updated by the UDC operating system from its local memory to dual port memory after each task is run Registers within this range written to by an AutoMax task are read by the UDC operating system from dual port memory and copied into the UDC local memory at the beginning of each scan in order to have a consistent context for evaluation See figure 3 1 WARNING IF YOU USE DOUBLE INTEGER VARIABLES YOU MUST IMPLEMENT A SOFTWARE HANDSHAKE BETWEEN THE TRANSMITTER AND THE RECEIVER TO ENSURE THAT BOTH THE LEAST SIG
112. rror Code N A LED N A Description Set this register to the number that will represent 1 OV The maximum allowable value is 32767 1017 UDG Module Meter Port 4 Minimum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDG Error Code N A LED N A Description Set this register to the number that will represent 1 0V The minimum allowable value is 32768 3 47 3 7 Interrupt Status and Control Registers Registers 2000 2047 This view is used to configure registers that control the operation of interrupts to a task on an AutoMax Processor in the rack and to enable CCLK in the rack These registers are used for Drive A and B Only one UDC task should write to these registers Note that the status of these registers is not retained after a Stop All 2000 Interrupt Status Control Register Hex Value N A Var Name UDC_ISCR Range N A Access See individual bits UDC Error Code N A LED N A Description The Interrupt Status Control register contains the following information Only bit 6 can be written to by the user All other bits are read only Bit 0 Hex Value 0001 H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description Interrupt Line Identification Bit 1 Hex Value 0002H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description Interrupt Line Identification Bit 2 Hex Val
113. rt setup via an application task or via I O Monitor 3 43 3 44 Meter Port 1 1002 UDC Module Meter Port 1 Register Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description UDC register number 0 2044 to be mapped to meter port 1 1003 UDC Module Meter Port 1 Bit Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Bit number of the UDC register specified in register 1002 that is to be mapped to port 1 Enter a value of 100 bit 00 to 115 bit 15 as required Enter a value of zero if all of the register s bits are to be displayed 1004 UDC Module Meter Port 1 Maximum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Set this register to the number that will represent 1 OV The maximum allowable value is 32767 1005 UDC Module Meter Port 1 Minimum Value Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Set this register to the number that will represent 1 OV The minimum allowable value is 32768 Meter Port 2 1008 UDC Module Meter Port 2 Register Number Register Hex Value N A Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description UDC register number 0 20
114. sk The programmer provides this information by Entering the drive parameters Configuring the registers in the UDC module e Defining the values of the pre defined local tunables e Writing the UDC task This manual describes the configuration and programming necessary to control SD3000 drives Refer to the publications listed in section 1 1 for detailed descriptions of the hardware components of an SD3000 drive system The AutoMax Programming Executive V3 4 M N 570345 57C346 57C395 576397 or later is required to support the SD3000 drive Beginning with V3 5 Executive software drive regulators are sold separately The AutoMax Programming Executive instruction manual describes the Programming Executive software in detail This instruction manual assumes that you are familiar with the AutoMax Programming Executive software and makes references to it throughout This manual does not describe specific applications of the standard hardware and software The thick black bar shown at the right hand margin of this page will be used throughout this instruction manual to signify new or revised text or figures Related Publications Refer to the following Reliance Electric instruction manuals as needed J 3012 Digital I O Rail e J 3606 Remote I O Communications e 4J3672 2 Channel Analog Voltage Input Output Rail e J 3673 Analog Current Input Output Rail e 3675 AutoMax Enhanced BASIC Language e J 3676 AutoMax Control
115. so available These programs have been designed to provide years of effi cient in house training Available for playback at the user s convenience these videotape programs allow individual or groups to learn or review subjects at any time Printed reference materials come with all diagnostic and troubleshooting programs Training Courses INDUSTRIAL CONTROLS COURSES AutoMate 15 Maintenance and Programming AutoMate 20 Maintenance AutoMate 30 40 Maintenance AutoMate 20 30 40 Programming AutoMate 30 40 Advanced Programming AutoMax CLASSES D C Drives and Introduction to AutoMax DCS AutoMax Maintenance and Troubleshooting AutoMax D C Drive Distributed Power System DPS AutoMax D C Drive Four Card Drive Group AutoMax Programming Fundamentals AutoMax Drives Programming AutoMax Advanced Programming HR500 HR2000 AutoMax Dual Axis Control Regional Class Maintenance and Troubleshooting AutoMax DCS D C Drives and Systems Four Card Drive Group Regional Class Maintenance and Troubleshooting AutoMax Distributed Power Systems DPS Audio Visual Products AutoMate 35 PROGRAMMABLE CONTROLLER PROGRAMS TM2204 AutoMate 35 Programmable Controller Diagnostics using the CRT Videotape TM2205 AutoMate 35 Programmable Controller l O Functions and Troubleshooting Videotape VIDEO TRAINING PROGRAMS VMBA001 Fundamentals of A C Motors Videotape VMBV001 Concepts of Digital Controls Videotape wwsoo01 GP2000 Video Training Videotape
116. ssive input signal typically originates from the drive s coast stop circuitry and is required to turn on MCRQ register 101 1 101 bit 1 Bit 1 Hex Value 0002H Var Name M_FDBKO Range N A Access Read Only UDC Error Code N A LED AUX on the Resolver amp Drive I O module Description The M contactor Feedback bit reflects the status of the M contactor feedback input sig nal which is connected to the AUX IN1 input on the Resolver Drive I O module The status of this bit will be dependent upon the application When the input signal is present this bit is set Bit 2 Hex Value 0004H Var Name AUX_IN2 or INV_FLTO Range N A Access Read Only UDC Error Code N A LED AUX IN2 on the Resolver 8 Drive I O module Description The Auxiliary Input 2 bit reflects the status of 115 VAC auxiliary input 2 on the Resolver amp Drive I O module When the input signal is present this bit is on If an inverting fault breaker is used this bit is used to reflect the status of the inverting fault breaker input signal When the signal is present this bit is on Bit 3 Hex Value 0008H Var Name AUX_INSO or AIR LOSO Range N A Access Read Only UDC Error Code N A LED AUX INS on the Resolver amp Drive module Description The Auxiliary Input 3 bit reflects status of 115 VAC auxiliary input 3 on the Resolver amp Drive module When the input signal is present this bit is on If Power Mo
117. ster 101 1 101 AutoMax tasks can access registers in the UDC s dual port memory in the same way as tasks on the UDC module itself i e by declaring them COMMON 4 2 UDC Tasks UDC tasks operate on registers in the UDC dual port memory described in chapter 3 as well as on local task specific variables in order to control some application variable e g speed and to calculate the required reference values for the selected control algorithm The UDC task is sometimes referred to as an outer or major control loop Note however that there may be more than one outer loop per task In this case the control loops are nested or cascaded within the UDC task UDC tasks must be written in the Control Block language a language designed specifically for drive control To differentiate them from Control Block tasks written for AutoMax Processors they must be specified as UDC tasks in the Programming Executive software Like Control Block tasks on AutoMax Processors UDC tasks can include a number of BASIC language statements and functions however those that allow task suspension or delay are not supported UDC tasks are created compiled loaded and monitored in the same way as Control Block tasks for AutoMax Processors UDC task variables can be monitored set tuned and forced like AutoMax task variables Note that the UDC module is accessed for monitoring and loading purposes through the serial port on the leftmost AutoMax Processor or
118. sts The block calculates a rise in temperature based on current feedback When operating above 10095 if the rise in temperature exceeds the programmed limit the OVERLOAD output will turn on After the overload condition is detected the rise in temperature must return to the 10096 condition before the drive will be allowed to turn on again The operation of the block is programmed through four block input parameters LIM BAR THRESHOLD TRIP TIME and I FDBK The value used for LIM BAR must be the same value entered as the motor overload ratio during drive parameter configuration The value used for THRESHOLD selects the percent of full load current at which overload is detected The value used for TRIP TIME selects the time in seconds within which the block must detect an overload after a step from 10096 current to LIM BAR The main input to the THERMAL OVERLOAD block is I FDBK I FDBK represents current feedback from the PMI in counts register 21 14 21 1 scaled so that LIM BAR is 4095 counts The main output from the block is OVERLOAD This boolean will be turned on when a thermal overload is detected The OVERLOAD output must be programmed in a Ladder Logic task to turn off the drive when the fault is detected The block also has an output called CALC RISE Current feedback is squared scaled passed through a Lag filter and then written to CALC RISE Consider an example in which LIM BAR is defined to be 15096 of full load current THRESHOLD
119. synchro nized after you have turned CCLK on In this case the feedback data from the PMI is not current This bit should normally be used only in the start permissive logic for the drive which must be true only once to start the drive It does not have to be used in the run permissive logic for the drive which must be true during the entire execution of the task Note that applications that require very tight synchronization between the UDC module and the PMI positioning applications may require the use of this bit in the run permissive logic Refer also to the Communication Lost fault bit description register 202 1 202 bit 15 Bit 15 Hex Value 8000H Var Name PMI_OKO Range N A Access Read Only UDC Error Code N A LED N A Description The PMI Processor sets the PMI Operating System Loaded bit when the operating sys tem has been successfully downloaded from the UDC module to the PMI Processor after power up 3 23 3 24 201 201 NO Status Register These bits indicate the current state of the inputs on the Resolver amp Drive I O module Bit 0 Hex Value 0001 H Sug Var Name RPI Range N A Access Read Only UDC Error Code N A LED RPI on the Resolver amp Drive I O module Description The Run Permissive Input bit reflects the status of the run permissive input signal con nected to pin A on the DRIVE I O connector When the signal is present this bit is set The run per mi
120. t Counter Register Usage for a 2 Output 2 Input Analog Rail Module Registers Registers Description 4 16 Port 0 Fault Register 10 22 Port 1 Fault Register Bit 4 Analog Channel 2 Input Over Range Bit 5 Analog Channel 2 Input Under Range Bit 6 Analog Channel 3 Input Over Range Bit 7 Analog Channel 3 Input Under Range Bit 8 No device plugged into a configured port Bit 9 Bad ID code device other than a rail is plugged into the port Bit 10 PMI interface is not ready Bit 11 Bad rail communication check bits received 17 Port O Check Bit Fault Counter Register 11 23 Port 1 Check Bit Fault Counter Register The register can be reset by setting bit 9 of the Warning Reset register 100 1100 3 2 UDC PMI Communication Status Registers Registers 80 89 1 080 089 The UDC PMI Communication Registers display the status of the fiber optic communications between the UDC module and the PMI Two consecutive errors will be indicated by a communication fault and the drive will stop Refer to register 202 1 202 bit 15 for more information Note that the communication Status registers are for system use only and can only be monitored They cannot be defined during configuration for access within the application task The status of these registers will be retained after a Stop All 80 1080 UDC Module Ports A B Status Register The UDC Module Ports A B Status register contains bits which describe any errors or warnings re ported on the UDC module rela
121. t is set when the armature current feedback val ue is greater than the Max Current Limit value plus 75 entered as a configuration parameter Bit 5 Hex Value 0020H Sug Var Name FLT_CONO Range N A Access Read Only UDC Error Code 1005 LED N A Description The Conduction Timeout Fault bit is set if CM RUN register 100 1 100 bit 0 is turned off and discontinuous conduction is not detected within 2 seconds 202 202 Drive Fault Register Continued Btt 6 Hex Value 0040H Var Name FLT_FLDO Range N A Access Read Only UDC Error Code 1006 LED PM FLT on the PMI Processor module Description The Field Loss Fault bit will be set when e The field current feedback value is less than the Field Loss Trip Point parameter value entered during configuration for 5 times the electrical time constant of the field This assumes FLD RUNQG register 100 1 100 bit 4 has been turned The field current feedback value dips below the Field Loss Trip Point parameter for 30 msec after the field has been turned on Bit 7 Hex Value 0080H Var Name FLT_TACO Range N A Access Read Only UDC Error Code 1007 LED FDBK OK on the Resolver amp Drive I O module Description The Speed Feedback Loss Fault bit is set when the motor s CEMF is greater than 4096 of the rated armature voltage value entered as a configuration parameter and the speed feedback signal is less than 596 of the motor base speed as entered
122. ta Field PM Data Speed Safety Data Speed Feedback Data Motor Base Speed RPM Meter Port Selection Over Speed Trip RPM Tach Volts at Over Speed Trip Figure 2 5 Speed Feedback Parameter Entry Screen With A Resolver Selected Slot 1 UDC Parameter Entry SD3000 6 Pulse Current UDC Drive Speed Feedback Type e Drive A O Drive B O No Speed Feedback Resolver en 8 Analog Tach Armature Data Field PM Data Speed Safety Data 6 Speed Feedback Data Motor Base Speed RPM Meter Port Selection Over Speed Trip RPM Resolver Type O None Ox 2 Figure 2 6 Speed Feedback Parameter Entry Screen With An Analog Tachometer Selected Speed Feedback Tvpe Selections WARNING THE USER MUST ENSURE THAT THE CORRECT FEEDBACK TYPE HAS BEEN SELECTED DURING CONFIGURATION IF NO SPEED FEEDBACK HAS BEEN SELECTED THE USER MUST PROVIDE AN INDEPENDENT METHOD OF OF DETECTING OVERSPEED OTHERWISE A FEEDBACK LOSS WILL NOT BE DETECTED RESULTING IN MOTOR OVERSPEED FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURYAND IN DAMAGETO OR DESTRUCTION OF THE EQUIPMENT No Speed Feedback If you select No Speed Feedback which is the default you do not have to enter Motor Base Speed Overspeed Trip Point or Tach Volts at Over Speed Trip however you can select a resolver for positioning purposes Note that if you select No Speed Feedback the PMI Processor
123. ted to UDC PMI communication on Port A and Port B These bits are latched when set and will remain set until a fault reset or warning reset is issued Bit 0 Hex Value 0001 H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Invalid Receive Interrupt bit is set when the interrupt generated by the Universal Serial Controller USC is not properly marked Two consecutive errors of this type will result in a communication fault 80 1080 UDC Module Ports A B Status Register Continued Bit 1 Hex Value 0002H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The No End of Frame Status Received bit is set if the USC does not report an End of Frame condition when the receive interrupt is generated Bit 2 Hex Value 0004H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The CRC Framing Error bit is set when the USC reports a CRC or Framing error on the last frame message received Bit 3 Hex Value 0008H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Overrun Error bit is set when the USC reports a receive first in first out overrun Bit 4 Hex Value 001 OH Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The DMA Format Error bit is set if the length of the received message do
124. tem to correspond only to the 2 15 HP and 16 60 HP Power Modules listed below These four D C Amp ratings must NOT be used for other Power Modules or the voltage feedback sensed by the PMI operating system will be incorrect For these D C Amp Ratings Use Only These Power Modules 25A and 27A 8036004 SRx or 80361 SRx 1 OOA and 125A 803601 1 SRx or 80361 l I SRx J l RE 18571 Printed in U S A Technical Writing Forward To Reliance Electric Internal V S Drives Technical Writing Group 24701 Euclid Ave Cleveland OH 44117 DIF V S DRIVES DOCUMENTATION IMPROVEMENT FORM Document Numberz Page Number s Comments Please give chapters page numbers or specific paragraphs that the change will affect Include markups from the document or attach additional pages if necessary What will this improvement suggestion provide Originator City J State ZIP Company _____________________ ___ _____________ Address Date Technical Writing Internal Use Follow Up Action Thank you for your comments ZA 2250 TRAINING AND AUDIO VISUAL PRODUCTS Reliance Electric offers a wide variety of Industrial Training courses for electricians electronic technicians and engi neers who are responsible for the installation repair and maintenance of production equipment and systems Professional quality A V Programs are al
125. ter contains the number of messages received by the UDC module on Port A and Port B This is a 16 bit value that rolls over when it reaches its maximum 82 1 082 UDC Module Ports CRC Error Count Register Hex Value N A Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description This register contains the number of messages with CRC errors received by the UDC module on Port A and Port B 83 1 083 UDC Module Ports A B Format Error Count Register Hex Value N A Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description This register contains the number of messages with format errors received by the UDC module on Port A and Port B 3 9 3 10 84 1 084 PMI A B Status Register The PMI A B Status register contains bits which describe any errors or warnings reported by the PMI related to UDC PMI communication on PMI A and B These bits are latched when set and will remain set until a fault reset or warning reset is issued Bit 0 Hex Value 0001 H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The Invalid Receive Interrupt bit is set when the interrupt generated by the Universal Se rial Controller USC is not properly marked Bit 1 Hex Value 0002H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description The No End of Frame Status Received bit is
126. test switches and LED indicators This view is also used to configure the UDC module s D A meter ports e The Interrupt Status and Control Registers view is used to configure the registers that control a user defined interrupt to an AutoMax task and enable the CCLK signal on the backplane The Gain Data values that are used by the PMI are NOT mapped to the UDC module s dual port registers The gain values are held in local tunables with reserved names which must be defined in the UDC task for the drive A or B The programmer must use the pre assigned local tunable reserved names described in Appendix B of this manual Note that register values are generally in the appropriate engineering units and that the variable names provided here are suggestions only your variable names may be different Duplicate common variable names are not permitted within any one rack Table 3 1 lists the configuration views in the AutoMax Programming Executive the registers to be configured in each and the section of this instruction manual in which the registers are discussed Table 3 2 lists the UDC dual port registers in numerical order Register Referen nventions in this Ch r Register numbers will be shown using the following convention XY where X is the drive A register number and Y is the drive B register number Note that the Interrupt Status Control registers and the Application registers are the same for both drive A and drive B Most register bit des
127. that the drive parameters will be retained by the UDC module during a Stop All fault or command in the rack Once a UDC module has been added to the rack use the Zoom In command to begin entering the drive parameters Refer to the AutoMax Programming Executive instruction manual for more information on Zooming in and out Use the following procedure to enter the drive parameters Section 2 3 describes how to load the drive parameter files when you are finished Note that if you enter drive parameter data that is unexpected or out of range a warning or error message will appear on the screen A warning message indicates that the data you have just entered will be accepted by the Programming Executive and you will be able to generate drive parameter files however you may experience degradation of drive performance An error message indicates that the data you have just entered is unacceptable and you will not be able to generate drive parameter files Step 1 Zoom into the UDC module The Power Module Interface PMI screen will be displayed You can also access this screen directly by double clicking the UDC module This screen shows either one or two PMI diagrams depending upon the information you previously entered One diagram will be shown for drive A and one for drive B if used Each PMI diagram will show two rail ports 0 and 1 and the analog or digital rails that are connected to the PMI Initially no rails are connected
128. the UDC module 0 Off 1 On Bit 12 Hex Value 1 000H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED DRV B FLT on the UDC module Description Status of the Drive B Fault LED on the UDC module 0 Off On 3 41 3 6 2 UDC Module Meter Port Setup Registers Registers 10014017 Registers 1001 1 017 are used to configure the UDC module s meter ports This configuration determines what variables from the UDC module s dual port memory are to be displayed on the meter ports at the end of the UDC scan At system power up the output values of the ports are reset to zero To map a UDC variable to a specific meter port at power up refer to table 3 7 and use the following procedure Note that the setup register configurations are retained during a Stop All Table 3 7 UDC Module Meter Port Setup Registers UDC Module Meter Port Setup Registers Meter Meter Meter Meter Port 1 Port 2 Port 3 Port 4 Variable Register Number Register 1002 1006 1010 1014 Bit Number Register 1003 1007 1011 1015 Maximum Value Register 1004 1008 1012 1016 Minimum Value Register 1005 1009 1013 1017 Change Setup Register 1001 1001 1001 1001 For each meter port Step 1 Place the register number of the variable you wish to display in the appropriate Variable Register Number register Step 2 If an individual bit of the register is to be displayed enter it in the Bit Number register as 100 bit 00 to 115 bit
129. thermal overloads protecting motors having a 1 O service factor trip at load currents no greater than 115 of full load To meet NEC requirements the THRESHOLD block parameter has a default value of 11496 and should not be set higher Refer to instruction manual J 3676 for more information 4 2 2 Local Tunable Variables 4 2 2 1 A set of local tunable variables with reserved pre defined names is used to store different types of values for use in drive control For a description of the local tunable variables used in SD3000 drives refer to Appendix B All pre defined local tunables must be defined in each UDC task using the BASIC language LOCAL statement in order for the task to be loaded onto the UDC module Although all of these variables are not necessarily used in the UDC task itself they must be defined there in order to provide a mechanism for passing the values between the UDC module and the PMI For convenience all these variables are already defined in the UDC task skeleton file in the AutoMax Programming Executive with HIGH LOW STEP and CURRENT values Your application task must define these variables using the same HIGH LOW and STEP limit values as the ones found in the skeleton task Note that you can only change the CURRENT value in the application task If the UDC operating system needs to clamp a value at the higher or lower limit it changes the actual value in the task and writes
130. tive Field Power Module is being used a negative value in this register will turn on the reverse bridge The actual reference value will be clamped at the Maxi mum Amps parameter value entered during configuration Refer to registers 21 211 current feed back in counts registers 2121 212 current feedback in amperes and registers 100 1 100 bit 11 disable field weakening for more information 1061 106 PMI D A Output Register Hex Value N A Sug Var UDC DA96 Range N A Access Read Write UDC Error Code N A LED N A Description The value in the PMI D A Output register is transmitted to the PMI Processor at the end of every UDC task scan Note that a task must copy the desired value into this register The value can then be displayed on one of the four PMI Processor meter ports This register can contain any vari able in the AutoMax system as long as it is a 16 bit integer Floating point or double integer values cannot be displayed on the PMI Processor s D A meter ports 3 4 Feedback Registers Registers 200 299 1200 1 299 The Feedback Registers view is used to configure the feedback registers that display the current status of the drive These registers are updated by the PMI Processor and sent to the UDC module over the fiber optic link before every scan of the UDC task The status of these registers is retained after a Stop All 200 1 200 Drive Status Register These bits indicate the current state
131. tor this bit is controlled by the programmer and the D C contactor must be controlled by auxiliary inputs and outputs on the Resolver amp Drive I O module See register 101 1 101 bit 4 and register 200 1 200 for the auxiliary output and input bits Bit 2 Hex Value 0004H Sug Name EXT LED Range N A Access Read Write UDC Error Code N A LED EXT FLT LED on the PMI Processor module Description The External Fault LED bit is set by the application task to turn on the EXT LED on the PMI Processor module Bit 4 Hex Value 001 OH Sug Var Name AUX OUT Range N A Access Read Write UDC Error Code N A LED AUX OUT LED on the Resolver amp Drive I O module Description The auxiliary output bit is set to turn on the auxiliary output on the Resolver amp Drive I O module 3 17 3 18 1011 101 NO Control Register Continued Bit 6 Hex Value 0040H Sug Var Name RES CALO Range N A Access Read Write UDC Error Code N A LED N A Description The Enable Resolver Calibration bit is set to start the test that determines the resolver s balance value This value will be stored in the pre defined local tunable RES BAL This bit is edge sensitive The test will turn off if the bit is turned off Note that this calibration test should only be executed at one half base speed Refer to register 201 1 201 bit 7 for more information on the calibration test complete bit Refer to the Distributed Power D
132. ture ID test in register 100 1 100 ARM TE Armature Electrical Time Constant Default Current Value 0 Low Limit 0 High Limit 5000 Step 1 The value in this variable is the electric time constant of the motor It is scaled in milliseconds times 10 so that a time constant of Te of 10 milliseconds has a value of 100 The largest value that can be stored in this variable is 0 5 seconds This value can be generated automatically by commanding the armature ID test in register 100 1 100 The ID test will provide a time constant value that takes into account the entire circuit providing power to the motor and may be different from the time constant provided by the manufacturer on the motor nameplate B B 2 Appendix B Continued Field Minor Loop Crossover Frequency Default Current Value 15 Low Limit 0 High Limit 75 Step 1 The value in this variable selects the desired response of the field regulation loop It is used by the field current regulation algorithm running on the PMI Processor to keep the CEMF value constant when operating above the base motor speed It is scaled in radians per second The higher the value the more quickly the drive responds to a change in field reference current Also note that the higher the value the less stable the system response becomes FLD R Field Resistance Default Current Value 0 Low Limit 0 High Limit 32767 Step 1 The value in this variable 15 th
133. u cannot attach a Local I O Head to the PMP s rail ports You can however mix input and output modules in a Digital I O Rail You can also mix rail types i e add both a Digital I O Rail and an Analog Rail rail mode only to a PMI Select the Configure Variables option from the Configure menu in order to configure the variables for the attached rails Zoom out to return to the PMI screen Use the Configure Parameters option to access the Parameter Entry screens Assuming you are configuring an SD3000 drive there are four screen displays Armature Power Module Data 1 Phase Field Power Module Data Speed Feedback Data and Meter Port Selection See figure 2 1 Each of these screens is described in detail in the following sections 2 2 1 through 2 2 4 Note that the AutoMax slot number of the UDC module is shown at the top of the screens The screens prompt for specific information depending upon the item that is being configured When you have made entries for the drive parameters on all of the parameter entry screens you should select the Verify option displayed at the bottom of the screen If any of the values you entered are invalid or out of range the parameter that is invalid will be highlighted so that you can change the value When you have finished entering drive parameters select Save to save the values to the database Slot 1 UDC Parameter Entry SD3000 6 Pulse Current UDC Drive de This area contains sp
134. ue 0004H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description Interrupt Allocated Bit 4 Hex Value 001 OH Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description Interrupt Generated This Scan 3 48 2000 Interrupt Status Control Register Continued Bit 5 Hex Value 0020H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Description CCLK Counting Bit 6 Hex Value 0040H Sug Var Name N A Range N A Access Read Write UDC Error Code N A LED N A Description Enable CCLK on the Multibus Backplane CCLK must be enabled in the rack for the UDC module to execute its task s and communicate synchronously with the PMI Only one module per rack should enable CCLK If CCLK is enabled on multiple modules in the rack an overlap error will result error code 38 Other modules that can enable CCLK include the M N 57C409 576421 and the 57C411 The UDC module uses CCLK to determine when it should run its tasks CCLK is also used as the time reference for all UDC modules in the rack so that they are all synchronized to start at deterministic time periods If interrupts to the AutoMax Processor are required register 2001 must be set to the desired value before CCLK is enabled Bit 7 Hex Value 0080H Sug Var Name N A Range N A Access Read only UDC Error Code N A LED N A Descripti
135. ue Note that the PMI meter ports have 8 bit resolution and are updated on the average every 1 O millisecond Refer to the Power Module Interface Rack instruction manual for more information about the PMI meter ports Refer to section 3 6 2 1 for information about resolution of data Port Not Used e Armature Current Reference Counts 4095 current limit e Armature Current Feedback Counts 4095 current limit Armature Current Feedback Amps x 10 e Armature Voltage Volts e Armature Maximum Firing Angle y Sec e Armature Firing Angle u Sec e Armature Minimum Firing Angle u Sec Field Current Reference Counts 4095 current limit Current Feedback Counts 4095 current limit e Field Current Feedback Amps x 100 e Field Voltage Volts e Field Maximum Firing Angle Sec e Field Firing Angle u Sec e Field Minimum Firing Angle Sec e Counter EMF Voltage Volts AC RMS Line Voltage Volts e User Analog Input Counts 2048 to 2047 1 10V Speed Feedback RPM e Application Data Units e Rail Port 0 Channel 0 Counts e Rail Port 0 Channel 1 Counts e Rail Port 0 Channel 2 Counts e Rail Port 0 Channel Counts e Rail Port 1 Channel 0 Counts e Rail Port 1 Channel 1 Counts Rail Port 1 Channel 2 Counts e Rail Port 1 Channel 3 Counts Analog input from the Resolver and Drive l O module Refer to register 2141 214 for more information
136. ure Power Module Data Screen 2 4 2 2 2 Field Power Module Data Screen 2 2 6 2 2 3 Speed Feedback Data Screen ae Bre SA deat 2 7 2 2 4 Meter Port Selection Screen 2 10 2 3 Generating the Drive Parameter Files and Printing Drive Parameters 2 12 3 0 Configuring the UDC Module s Registers esee 3 1 3 1 Rail l O Port Registers Registers O 23 3 4 3 2 UDC PMI Communication Status Registers Registers 80 89 1080 1 089 3 6 3 3 Command Registers Registers 100 1 99 1 100 1199 3 14 3 4 Feedback Registers Registers 200 299 1200 1299 3 21 3 5 Application Registers Registers 300599 Every Scan Registers 1300 1 599 Every Nth Scan 3 38 3 6 UDC Module Test I O Registers Registers 1000 1 017 3 40 3 6 1 UDC Module Test Switch Inputs Register Register 1000 3 40 3 6 2 UDC Module Meter Port Setup Registers Registers 1001 1 017 3 42 3 6 2 1 Resolution of Meter Port Data 3 42 3 7 Interrupt Status and Control Registers Registers 2000 2047 3 48 4 0 Application Programming for DPS Drive
137. ust load the operating system s to the AutoMax Processor s at the same time or before you load the UDC module operating system You have the option of loading the operating system to the UDC module in a slot you specify or to all UDC modules in the rack It is possible to re load a single UDC module s operating system without having to re load the operating systems to all of the UDC modules in the rack The leftmost AutoMax Processor in the rack will check for compatibility between the AutoMax operating system and the UDC operating system If you replace a UDC module with another UDC module that already contains an incompatible operating system the new UDC module will be disabled and its OS OK LED will be turned off 5 2 Loading the Drive Parameters and UDC Tasks The drive parameters specified when the UDC module is configured can be thought of as the UDC configuration Like the AutoMax Processor the UDC module must have its configuration loaded before it can execute any tasks You can load the drive parameters and UDC tasks to the UDC by selecting L for Load from the ON LINE Transfer menu Several options which are briefly described below will be displayed on the screen You have the option By selecting A for All to automatically load the rack i e AutoMax Processor configuration the drive parameters for all the UDC modules in the rack and all tasks for the rack including all UDC tasks You have the option of loading the
138. values including Feed back registers UDC PMI communication status retained retained registers UDC Error Log info Output values including Command registers Application registers reset to 0 reset to 0 ISCR registers Scan per interrupt register Scans per interrupt counter Appendix E Power Module Model Numbers and Parameter Default Values 230 Line Voltage S6 Drive Model Number D C Output Volts D C Supa Amps CT Turns Ratio as 30300 RB 2 10 1575 y 30301 1s 830 30301 RE 1520 145 TET 30304 RD 30 55 10 _ Sel Sei T User supplied external CTs must be provided 320 480 3860 l 685 850 7770 1 850 000 7710 1 30302 25 75 20 55 ____240 230 VAC Line Voltage S6R Drive Model Number HP EM D C Output Volts D C Output Amps CT Turns Ratio 3031018 175 20 1027 100 30510 8 zots 3 9 30311 15 30 100 5007 30311 RE 1520 111 1000 30312 RE 25 75 20 55 0 265 20008 3860 30814 RB 200250 12516 240 685850 7770 SOSH RD 250300 185 220 240 8501000 77703 ___ 405040 Sonn so 2081 osii Sena so so 417 ____ 05 SeRixA 5 wo 833 m5510 sezsa 209 2000 Senaoa 5o 35 3093 C soseo so 59 o 8405810 568 15004 500 1250 105001
139. ve Parameter Files option in the Generate Files dialog box and then select OK A file containing the newly entered drive parameters will be created The file will be named PARAMXxx POB where xx is the slot number of the UDC module Note that the drive parameter files must be loaded to the rack before or at the same time the UDC application tasks are loaded to the rack Refer to the AutoMax Programming Executive instruction manual for more detailed information You can print the drive parameters for a UDC module you specify by using the Print command from the Rack menu in the System Configurator Refer to the AutoMax Programming Executive instruction manual for step by step instructions 3 0 CONFIGURING THE UDC MODULE S REGISTERS ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL ADJUST OPERATE OR SERVICE THIS EQUIPMENT READ AND UNDERSTAND THIS MANUAL AND OTHER APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE WARNING ONLY QUALIFIED RELIANCE PERSONNEL OR OTHER TRAINED PERSONNEL WHO UNDERSTAND THE POTENTIAL HAZARDS INVOLVED MAY MAKE MODIFICATIONS TO THE VARIABLE CONFIGURATION ANY MODIFICATIONS MAY RESULT IN UNCONTROLLED MACHINE OPERATION FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN DAMAGE TO EQUIPMENT AND BODILY INJURY WARNING REGISTERS
140. verrun error 4 DMA format error 5 Transmitter underrun 6 CCLK comm synch error 8 UDC CCLK comm synch error 9 Multiplexed data verification failure 12 Invalid PMI start OS address 13 Insuff PMI memory to load PMI OS 14 Invalid PMI load address 15 PMI OS overflow 85 1085 good msg recvd count 86 1086 PMI CRC error count 87 1087 format error count 61 1081 82 1082 83 1083 84 1084 88 1088 Commilink status 89 1089 UDC transmitted msg count COMMAND REGISTERS A B 1004 100 Drive control Bii 0 Current minor loop run CML_RUN 1 Enable armature ID test CML_ID 2 Enable armature alpha test CML_AT 3 Armature alpha test reverseCML_ATR 4 Field regulator run FML_RUN 5 Enable field ID test FML_ID 6 Enable field alpha test FML_AT 7 Field alpha test polarity FML_ATR 8 Fault reset FLT_RST 9 Warning reset WRN_RST 11 Disable field weakening NO_FLDW 15 UDC task running status UDC_RUN Bit 15 in register 100 1 100 must not be written to by the programmer All other bits in register 100 1 100 are read write 101 11011 0 control Bit 1 M contactor output MCR 2 External fault LED EXT_LED 4 Auxiliary output AUX_OUT 6 Enab rslvr cafib test RES CAL 8 Enable external strobe STR_ENA 9 Enab ext str fall edge STR_ENF 10 Disable broken wire detect NO 15 UDC portloopback test UDC LBO 1021 102 Armature test firing angle ALPHA 103 1103 Armature current reference CML_REF
141. yed value is equal to the num ber of amps times 10 For example 50 1 amps would be displayed as 501 If the configured motor amps value times the overload ratio plus 7596 is greater than 3000 amps then the feedback is dis played in amps 2091 209 Armature Voltage Feedback Register Hex Value N A Var Name ARM VFB DC Volts Range N A Access Read Only UDC Error Code N A LED N A Description The Armature Voltage Feedback register displays the measured armature voltage A value of 1 is equal to 1 volt 21 210 Counter EMF register Hex Value N A Var Name EMF_VFB DC Volts Range 32768 to 32767 Access Read Only UDC Error Code N A LED N A Description The Counter EMF register displays the measured counter EMF voltage A value of 1 is equal to 1 volt 21 1121 1 Field Minor Loop Feedback Register Hex Value N A Var Name FML_FB Range 32768 to 432767 Access Read Only UDC Error Code N A LED N A Description The Field Minor Loop Feedback register displays the measured field current DC Amps in counts A value of 4095 is equal to 10096 of the Motor Field Hot Amps value in the parameter entry screen 2121 212 Field Current Feedback Register Hex Value N A Name FLD IFB amps x 100 Range 32768 to 32767 Access Read Only UDC Error Code N A LED N A Description The Field Amps Feedback register displays the measured field current The

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